Rapidly-orodispersible tablets having an interior cavity

ABSTRACT

A rapidly-orodispersible dosage form comprising a porous, bound-powder matrix and one or more internal cavities is provided, as well as three-dimensional printing methods for making the same. Each internal cavity is configured to contain one or more payloads, particularly pharmaceutical medicaments, while isolating the payloads from the external environment outside of the dosage form. Each payload can be contained within its cavity in its native form without having to be combined with the bound-powder matrix or binding liquid. Dosage forms can disintegrate in water or saliva in less than two minutes, independently of the payload(s) or medicament(s) contained within. The dosage forms can be formed as unitary tablets, or as two-piece tablets comprising a container body and a lidding body that are secured together to isolate the one or more cavities and their payloads inside.

CROSS-REFERENCE TO EARLIER FILED APPLICATIONS

The present application is a divisional of U.S. application Ser. No.17/513,307 filed Oct. 28, 2021, issued as U.S. Pat. No. 11,433,022 onSep. 6, 2022, which is a continuation of International Application No.PCT/US2021/039137 filed Jun. 25, 2021, which claims the benefit of U.S.Provisional Application No. 63/044,740 filed Jun. 26, 2020, and U.S.Provisional Application No. 63/214,343 filed Jun. 24, 2021, the entiredisclosures of which are hereby incorporated by reference.

FIELD OF THE INVENTION

This invention is related to the field of manufacturing dosage or tabletforms for containing medicaments, pharmaceutical excipients, and otherpayloads.

BACKGROUND OF THE INVENTION

Solid oral dosage forms, particularly tablets and capsules, have longbeen a common administration route for a subject taking bothprescription and non-prescription medications. Active pharmaceuticalingredients (API) that can be synthesized and/or formed into solidpowders, particles, or agglomerates can conveniently be manufacturedinto tablets or capsules, and most people can swallow such dosage formswhole with a minimum volume of liquid, typically water.

However, a significant number of patients, including young and elderlypeople, have difficulties swallowing solid dosage forms, particularlydosage forms containing high dosages of API and/or excipients necessaryto support the API within the dosage form itself. Difficulty inswallowing leads to poor patient compliance. Some attempts to solve thisproblem have led to the development of oral liquid and injectableformulations, but stability, contamination, and inaccurate dosing haveall been drawbacks to using such dosage forms.

The production of rapidly dispersible solid oral dosage forms has beenanother potential solution for providing medication to those withdifficulties swallowing medication. Rapidly-orodispersible dosage formscan disperse or disintegrate in the mouth in a minimal amount of salivaor water. Such dosage forms can be easier to swallow and accuratelydose, and in some instances can provide a more rapid therapeutic action.U.S. Pat. No. 7,749,533 discloses a dosage form containing granulescontaining a drug, porous plastic substance, water penetration enhancer,binder and drug. The granules must be compressed in order to create thedosage form. U.S. Pat. Nos. 4,371,516 and 5,738,875 disclosefreeze-dried dosage forms, and U.S. Pat. No. 5,178,878 discloses asoft-compressed orodispersible dosage form. Effervescent dosage formsand quick-release coatings of insoluble microparticles are described inU.S. Pat. Nos. 5,578,322 and 5,607,697. Freeze dried foams and liquidsare described in U.S. Pat. Nos. 4,642,903 and 5,631,023. Melt-spundosage forms are described in U.S. Pat. Nos. 4,855,326, 5,380,473 and5,518,730. U.S. Patent Publication No. 2007/0218129 discloses animmediate release dispersible and orodispersible solid pharmaceuticalcomposition having the form of particles with a size lower than 710 μmupon dispersion into water, wherein the formulation is made by wetgranulation, and with disintegration times ranging from 53 to 60 sec.The disclosures of each of the patents and patent publications listedabove are incorporated by reference in their entireties.

Rapidly-orodispersible dosage forms have also been produced usingadditive manufacturing, including three-dimensional printing (3DP)platforms utilizing 3DP equipment assemblies and systems (see U.S. Pat.Nos. 6,471,992, 9,114,072, 9,314,429, 9,339,489, 9,463,160, 9,492,380,9,616,018, 9,669,009, 10,029,909, and 10,420,785, as well as U.S. PatentPublication Nos. 2003/0133975, 2012/0207929, 2017/0202807, and2017/0258763, the descriptions of which are incorporated by reference intheir entireties). 3DP platforms in particular can generally includesolid freeform fabrication and/or rapid-prototyping techniques in whichthin layers of powder are spread onto a surface and selected region ofthe powder are bound together by the controlled deposition (“printing”)of a liquid. This basic operation is repeated layer-by-layer, with eachnew layer formed on top of and adhered to the previously printed layer,to eventually make three-dimensional objects. When the printed objectshave sufficient cohesion, they may be separated from unbound powderwithin or surrounding the object.

Several systems and equipment assemblies for additively manufactured or3DP articles are commercially available or in use by others, forexample: Massachusetts Institute of Technology Three-DimensionalPrinting Laboratory (Cambridge, Mass.), Z Corporation's (now part of 3DSystems) 3DP and HD3DP™ systems (Burlington, Mass.), The Ex One Company,L.L.C. (Irwin, Pa.), Soligen (Northridge, Calif.), Specific SurfaceCorporation (Franklin, Mass.), TDK Corporation (Chiba-ken, Japan),Therics L.L.C. (Akron, Ohio, now a part of Integra Lifesciences),Phoenix Analysis & Design Technologies (Tempe, Ariz.), Stratasys, Inc.'sDimension™ system (Eden Prairie, Minn.), Objet Geometries (Billerica,Mass. or Rehovot, Israel), Xpress3D (Minneapolis, Minn.), and 3DSystems' Invision™ system (Valencia, Calif.). Non-limiting examples of3DP systems capable of forming rapidly-orodispersible tablets have beendescribed in U.S. Pat. Nos. 8,888,480, 9,517,591, 9,517,592, 9,610,735,9,908,293, 10,118,335, and 10,449,712, as well as U.S. PatentPublication Nos. 2018/0141275 and 2020/0001521, the disclosures of whichare incorporated by reference in their entireties.

Nonetheless, some API compounds are incompatible with the powder, thebinder material, or manufacturing conditions necessary to constructorodispersible dosage forms with sufficient hardness and friability towithstand storage and handling while also exhibiting a rapiddisintegration rate. Further, many additive manufacturing and 3DPsystems and techniques used to make dosage forms, includingrapidly-orodispersible forms, that include API compounds result inexcess API waste that often cannot be recovered. Therefore, thereremains a need for improved and more convenient rapidly-orodispersibledosage forms that can accommodate a larger assortment of API compounds,while also minimizing the waste of the API compounds themselves.

SUMMARY OF THE INVENTION

The present invention describes a porous article having one or moreinternal cavities disposed inside, each article comprising abound-powder material. The bound powder material can comprise aninterconnected matrix of particles of a powder material and a bindermaterial. Each of the cavities are isolated within a portion of theinterconnected matrix of the article. In articles with more than onecavity, each cavity can also be isolated from other cavities within thearticle. Any one or more of the internal cavities can contain one ormore payload materials. The payload material can be a differentcomposition than the composition of the bound-powder materialscomprising the interconnected matrix. The description that followspertains and is according to the present invention.

According to the present invention, the article can be arapidly-orodispersible dosage form, such as a tablet or capsule. Thebound-powder material, as well as the powder material and the bindermaterial, can be ingestible. The payload material contained within theone or more internal cavities can comprise one or more solidmedicaments, particularly powdered, particulate, crystalline orco-crystalline, hot melt extrusions, or agglomerated medicaments. Thepayload material contained can also comprise one or more liquid,semi-solid, paste, gel or flowable materials, any of which can be amedicament. Either or both of the matrix of the rapidly-orodispersibledosage form or the payload material within the one or more cavities canfurther comprise one or more pharmaceutically-acceptable excipients,non-limiting examples of which can include binders, disintegrationagents, dispersants, sweeteners, glidants, flavoring agents,surfactants, humectants, preservatives, antioxidants and diluents.Further, some materials comprised within the powder material and/orbinder material can have the characteristic of more than one type ofexcipient. As a non-limiting example, within dosage forms that compriseglycerin, the glycerin can exhibit characteristics similar to ahumectant, sweetener, preservative, lubricant, saponifier, or a solvent.

Any of the rapidly-orodispersible dosage forms described herein can beformed using additive manufacturing systems, particularlythree-dimensional printing (3DP) systems, using high-throughputcontinuous, semi-continuous, or batch manufacturing techniques, withminimal product loss, high efficiency, and high product reproducibility.Accordingly, the embodiments and features described herein provideadditive manufacturing and 3DP-based methods for formingrapidly-orodispersible dosage forms having one or more internal cavitiesconfigured to contain one or more pharmaceutical medicaments and/orpayloads within the dosage form.

The rapidly-orodispersible dosage forms can be formed using anyconventional additive manufacturing or 3DP freeform fabrication systemand/or equipment assembly that utilizes a build platform configured tobuild objects from a bed or other supply of powder material,particularly any of the systems or assemblies described in U.S. Pat.Nos. 6,471,992 and 8,888,480, the disclosures of which are incorporatedby reference in their entireties. Upon the completion of printing, eachdosage form can be separated from the unbound powder, and optionally atleast a portion of the unbound powder can subsequently be recycled toform additional dosage forms or additively manufactured objects.

The rapidly-orodispersible dosage forms can be formed using any additivemanufacturing or 3DP manufacturing systems and/or equipment assemblesconfigured for the preparation of objects within a depression in a buildplatform, particularly any of the systems or assemblies described inU.S. Patent Pub. No. 2018/0141275, the disclosure of which isincorporated by reference in its entirety. Dosage forms can be formed bya succession of a plurality of incremental layers formed independentlywithin each depression in the build platform, rather than in an openpowder bed. Following the completion of printing, the article can bedischarged from the depression, and can subsequently optionally bedried, separated from unbound powder, dedusted, and/or packaged.

The rapidly-orodispersible dosage forms can be formed using additivemanufacturing or 3DP manufacturing systems and/or equipment assemblesconfigured for forming of objects in situ within the depression of apackaging material, particularly any of the systems or assembliesdescribed in International Patent Publication WO2020/081561, thedisclosure of which is incorporated by reference in its entirety. Thepackaging can comprise one or more depressions, and in some embodiments,a pattern of a plurality of depressions. Non-limiting examples of suchpackaging are a blister pack and a disposable single-dose blister pack.

Any one of the rapidly-orodispersible dosage forms described herein cancomprise a porous, durable body comprising a bound-powder material,having one or more interior cavities. The bound-powder material cancomprise an interconnected matrix of at least one ingestible powdermaterial and at least one ingestible binder material. The matrix canhave a defined overall bulk density, disintegration (dispersion) time inaqueous fluid, dissolution time in aqueous fluid, and moisture content,which can be collectively tailored to provide a balance of improvedchemical stability, sufficient hardness, low friability and extremelyrapid dispersion time in a small volume of aqueous liquid.

The rapidly-orodispersible dosage forms are useful because they can beformed to withstand physical storage and handling, but undergo rapiddispersion/disintegration of its bound-powder matrix in the presence ofa small volume of liquid. The orodispersibility of any one of the dosageforms described herein can be characterized by how quickly the dosageform disintegrates in a small amount of aqueous fluid, typically in asubject's mouth, such as water, saliva, juice, milk, beverage, bodyfluid, soda or a combination thereof. The dosage form can disintegratein a small amount of water in a time ranging within 90 seconds, and bynon-limiting example, within 60 seconds, within 30 seconds, within 15seconds, within 10 seconds, and within 5 seconds. The small amount ofwater can be, by non-limiting example, one of at least 1 ml, at least 5ml, or at least 10 ml, and one of up to 50 ml, up to 20 ml, up to 15 ml,up to 10 ml, up to 5 ml, and up to 1 ml. In one embodiment, the smallvolume of water is a sip of water, having a volume of up to 50 ml, andas little as 1 ml or less.

An ingestible powder material as described herein can comprise one ormore powdered, particulate, crystalline, or agglomeratedpharmaceutically-acceptable excipients, including any of the excipientslisted above. In some embodiments, the one or more excipients comprisingthe ingestible powder material can be selected from the group consistingof a disintegration agent, a solid binder material, a dispersingmaterial, and a glidant, including combinations thereof. A non-limitingexample of an ingestible powder material is a blend comprising mannitol,microcrystalline cellulose, povidone, and colloidal silicon dioxide. Invarious embodiments, a portion of the ingestible powder material cancomprise a medicament compound, and in some embodiments, a particulatemedicament compound.

An ingestible binder material as described herein can be provided withinthe ingestible binding liquid, as described above, and/or within aprinting liquid. In some embodiments, the binding liquid can comprise aliquid component, non-limiting examples of which include an organicsolvent or water, that can dissolve and/or activate solid bindermaterial comprised within the ingestible powder material. When a bindingliquid is dispensed from a printing head, as is utilized in some3DP-based production methods, the binding liquid can alternatively becalled “printing liquid” or “printing fluid”. A binding liquid orprinting liquid can also comprise one or more medicaments or excipientsdissolved or suspended within the liquid. In some embodiments, the oneor more excipients can be a pharmaceutically-acceptable excipient, andcan be selected from the group consisting of a disintegration agent, aningestible binder material, a humectant, a sweetener or flavoring agent,a preservative, a solvent, and a surfactant, including combinationsthereof. A non-limiting example of a binding liquid, which optionallycan be used as a printing liquid in 3DP-based production methods, is aliquid composition comprising: water, isopropanol, glycerin, polysorbate20, and povidone.

The one or more interior cavities as described herein can eachindividually have a volume in a range of at least 1%, or by non-limitingexample, at least 5%, at least 10%, at least 15%, or at least 20%, or atleast 25%, of the volume of the dosage form, and up to 75%, or bynon-limiting example, up to 60%, up to 55%, up to 50%, of the volume ofthe dosage form. In an embodiment of the invention, which may be used incombination with any other embodiment described herein, the dosage formcan have a single interior cavity, two interior cavities, three interiorcavities, or more. The volumetric size of an interior cavity can beselected based on the overall volume and dimensions of therapidly-orodispersible dosage form, and the desired dosage amount of apayload material to be added into the interior cavity. The volumetricsize of the interior cavity can be at least 10 microliters, or at least25 milliliters, or at least 100 milliliters, and up to about 1milliliter, or up to about 500 microliters, or up to about 100microliters.

The one or more payload materials or payload medicaments, as describedherein, within a cavity or cavities within a dosage form, can have anymass, so long as it can be contained within its cavity, and is based onthe dosage requirements of the subject. As a non-limiting example, andin another embodiment, a dosage form configured for administration to ahuman or other mammal can comprise one or more medicaments or otherpayloads having a mass in a range from at least 1 about microgram, andup to at least about 5 grams. In another embodiment, a dosage formconfigured for administration of a larger mass amount, for example whenbeing administered to a large animal, non-limiting examples of which caninclude farm animals, such as horses or cows, or zoo animals, such aselephants or giraffes, can comprise one or more medicaments or payloadshaving a mass of up to 5 grams, or up to 10 grams.

In another embodiment, a dosage form can be configured foradministration of a medicament or other payload that may be difficult todose accurately in minute quantities, for instance, from at least 1microgram and up to 1 milligram. In one non-limiting example, a stocksolution of a known concentration of a medicament known to solublewithin a selected printing fluid can be formulated and subsequentlydiluted, either when forming the printing fluid directly or in one ormore dilutions prior to forming the printing fluid, to arrive at adesired concentration of the medicament within the dosage form.Similarly, and in another non-limiting example, a medicament can becombined and blended to uniformity along with one or more excipients toform a particulate mixture, which can used to form the bulk powdermaterial used to construct a rapidly orodispersible dosage form.

A rapidly-orodispersible dosage form, as described herein, can containone payload material comprising a medicament in a single interiorcavity, or two or more payload materials, either one or more comprisinga medicament in a single interior cavity, particularly when the two ormore payload medicaments are inert with respect to each other and can bestored in direct contact with one another within the same cavity of thedosage form. An embodiment of a rapidly-orodispersible dosage form,which may be used in combination with any other embodiment describedherein, can contain two or more payload medicaments separately in two ormore interior cavities, particularly when the two or more medicamentscan be administered as a co-therapy, but when stored together can reactwith each other or cause one of the medicaments to degrade prior tobeing administered. Similarly, and in various embodiments, a dosage formcan contain a medicament within an interior cavity, while alsocontaining a medicament interspersed within the powder material. Invarious embodiments, a medicament can be interspersed within the powdermaterial, while a solid excipient or other material, which may otherwisereact prematurely with the medicament and/or be protected fromenvironments outside the dosage form, is contained within the interiorcavity. In some embodiments of a rapidly-orodispersible dosage form,which may be used in combination with any other embodiment describedherein, instead of a medicament, the rapidly-orodispersible dosage formcan contain a placebo material within one or more interior cavities, theplacebo material intended to mimic the taste, texture, and overallexperience of a rapidly-orodispersible dosage form containing amedicament, but without having a pharmacologic effect. The placebomaterial can be an unbound powder material having the same compositionas the ingestible powder material in the bound-powder matrix.

In some embodiments, a rapidly-orodispersible, unitary,partially-enclosed dosage form is provided, having an internal cavity,comprising a container body with a unitary lid that encloses an internalcavity within the dosage form, and having a port opening within andthrough the container body (for example, through the base or theperipheral wall) or the unitary lid. The port opening is in fluidcommunication with the one or more internal cavities formed within thecontainer body. The port opening is typically that a portion of the lid,or that portion of the container body, when being formed from buildpowder material, where the particulate build powder material was leftunbound (for example, not contacted with printing or binding liquid)during the forming of the bound powder matrix of the lid or thecontainer body. Once the lid and container body have been formed, theunbound build powder in the portion of the lid or the container body isremoved to form the port opening. Any unbound powder material containedwithin the one or more interior cavity(ies) of the container body can beevacuated through the port opening.

The effective size or diameter of the port opening can be as large asneeded to evacuate unbound build powder than might be trapped inside thecavity of the partially-enclosed dosage form, following its manufacture,and can be as minimal in size or diameter as possible to simplify orimprove the subsequent closing and/or sealing of the port opening, oncemost or all of the unbound powder material has been evacuated, and thepayload material deposited into the internal cavity of the dosage form.The cross-sectional size of the port opening is typically sufficient ineffective size or diameter to evacuate the unbound powder material fromthe interior cavity by air fluidizing, vacuuming, or pouring the unboundpowder material out through the port opening, and sufficient in size topermit filling the evacuated interior cavity with a payload material.The partially-enclosed dosage form with the payload material depositedwithin the cavity can then be closed and sealed, by inserting ordepositing within the port opening a suitable water-soluble oringestible material. A rapidly-orodispersible, unitary,partially-enclosed dosage form can be prepared in an open print bed of a3DP assembly, or within a depression of a dosage form package, such as ablister package, or within a fixed-volume or variable-volume moldcavity.

In some embodiments of a rapidly-orodispersible dosage form, which maybe used in combination with any other embodiment described herein, arapidly-orodispersible dosage form can additionally comprise adissolvable barrier material, applied or coated onto at least a portionof an interior surface of the dosage form that forms a boundary for theone or more interior cavities. The dissolvable barrier material can bedisposed between the contents of an interior cavity and the bound-powdermaterial comprising the matrix, to inhibit or prevent the contents ofthe interior cavity from migrating into the bound-powder material, andpotentially out of the dosage form altogether. The dissolvable barriermaterial is selected from the group consisting of water-solublediluents, water-soluble binders, water-soluble film-formers, andwater-soluble gelling agents, and combinations thereof. The dissolvablebarrier material can comprise mannitol, sorbitol, xylitol, lactitol,erythritol, isomalt, povidone, copovidone, hydroxypropylcellulose,hydroxypropylmethylcellulose, carboxymethylcellulose, gelatin, casein,agar, guar gum, gellan gum, xanthan gum, locust bean gum, alginate,carrageenan, hydroxypropyl starch, pre-gelatinized starch, poloxamer,polyethylene glycol, polydextrose, or polyvinyl alcohol, includingderivatives and/or combinations thereof.

In some embodiments of a rapidly-orodispersible dosage form, which maybe used in combination with any other embodiment described herein, therapidly-orodispersible dosage form can be formed into anythree-dimensional geometric shape. In some embodiments, the dosage formcan be in the shape of an irregular or regular polyhedron, a prismhaving an “n” number of regular faces; for example, 3, 4, 5, 6, or 8regular faces, a prismatoid, a prismoid, a scutoid, a frustum, such as apyramidal frustum, a conical frustum, a spherical frustum, andfrustoconical sections. Non-limiting examples of dosage form shapes caninclude square, circular and elliptical cylinders. In other embodiments,a rapidly-orodispersible dosage form can have one or more roundedsurfaces, such as, as non-limiting examples, top and/or bottom roundedsurfaces, including spherical, ellipsoidal, and/or spherocylindrical(capsular) shaped surfaces. In particular, rapidly-orodispersible dosageforms formed with rounded surfaces, particularly spherocylindricaldosage forms, can be formed to mimic the capsular and ellipsoidal shapesof other common prescribed and over-the-counter medications. Thoseskilled in the art would appreciate that the above examples arenon-limiting, and that there are an infinite number of shapes into whicheach dosage form can be constructed.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, therapidly-orodispersible dosage form can be formed into a unitary dosageform, comprising a single bound-powder matrix that envelops and isolatesone or more interior cavities. The unitary dosage form can have one,two, three, or more internal cavities. A unitary dosage form or tablethas a matrix that is formed completely from a plurality of bound powderlayers, each bound powder layer formed by placing a layer of a powdermaterial over a previously-formed bound powder layer, and selectivelybinding the powder material together and to the previously-formed boundpowder layer, to form a next bound powder layer.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, therapidly-orodispersible dosage form can comprise two separate bodies,including a container body and a lidding body, that are secured togetherto form a two-piece tablet having one or more internal cavities. Thecontainer body can comprise and be formed using a first bound-powdermaterial, and the lidding body can comprise and be formed using a secondbound-powder material. The first bound-powder material can comprise aninterconnected matrix of a first powder material and a first bindermaterial, and the second bound-powder material can comprise a secondpowder material and second binder material. The first powder materialand the second powder material, and the first binder material and thesecond binder material, can be selected from the group consisting of anyof the powder materials and binder materials, respectively, describedabove. In some embodiments, the first bound-powder material and thesecond bound-powder material can comprise the same composition.

According to the present invention, a container body can have one ormore cavities, and include a base and a peripheral wall extending fromthe base and having an inner surface, an upper surface, and an externalsurface. The one or more cavities within the container body are boundedby the base and the inner surface of the peripheral wall.

According to the present invention, a lidding body can have anundersurface configured to be positioned over the upper surface of theperipheral wall, covering the one or more cavities to form internalcavities. In some embodiments, which may be used in combination with anyone or more of the embodiments described above and herein, theundersurface of the lidding body can comprise a peripheral portion andan interior portion, the interior portion including a projectionportion. The projection portion can extend below the peripheral portionand have an annular outer surface that is frictionally engaged with aportion of the inner surface of the peripheral wall. The lidding bodycan have a perimeter wall extending from the peripheral portion of theundersurface, the perimeter wall having a bottom surface and an innersurface, wherein the inner surface of the perimeter wall of the liddingbody is frictionally engaged with at least a portion of the externalsurface of the peripheral wall of the container body. In a furtherembodiment, the perimeter wall of the lidding body can extend along andfrictionally engage with the entire length of the peripheral wall of thecontainer body, giving the dosage form a planar bottom surface definedby the base of the container body and the bottom surface of theperimeter wall of the lidding body.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, the means forsecuring the lidding body to the container body can comprise an adhesivematerial disposed between at least a portion of the undersurface of thelidding body and the upper surface of the peripheral wall of thecontainer body. The adhesive material can be disposed between at least aportion of the annular outer surface of the projection portion of thelidding body and the inner surface of the peripheral wall of thecontainer body. The adhesive material can be disposed between theexternal surface of the peripheral wall of the container body and theinner surface of the perimeter wall of the lidding body that overlapsthe container body. In some embodiments, which may be used incombination with any one or more of the embodiments described above andherein, the adhesive material can be disposed between one or morelocalized or selected portions of any of the surfaces above. In onenon-limiting example, the adhesive material can be appliedintermittently and non-contiguously across one or more of the surfaces,in an amount sufficient to secure the lidding body and the containerbody together. In another non-limiting example, the adhesive materialcan be applied continuously along the circumference of the undersurfaceof the lidding body and/or the upper surface of the peripheral wall ofthe container body, in order to form a seal between the lidding body andthe container body in the assembled dosage form.

An adhesive material can be selected from the group consisting ofwater-soluble diluents, water-soluble binders, water-solublefilm-formers, and water-soluble gelling agents, including combinationsthereof. Non-limiting examples of adhesive materials include mannitol,sorbitol, xylitol, lactitol, erythritol, isomalt, povidone, copovidone,hydroxypropylcellulose, hydroxypropylmethylcellulose,carboxymethylcellulose, gelatin, casein, agar, guar gum, gellan gum,xanthan gum, locust bean gum, alginate, carrageenan, hydroxypropylstarch, pre-gelatinized starch, poloxamer, polyethylene glycol,polydextrose, or polyvinyl alcohol, or derivatives thereof, andcombinations thereof. In some embodiments, which may be used incombination with any one or more of the embodiments described above andherein, the adhesive is moisture-activated and is applied as a solution,dispersion, or gel. In some embodiments, which may be used incombination with any one or more of the embodiments described above andherein, the adhesive is moisture-activated and is applied as a solution,dispersion, or gel via inkjet printhead.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, the adhesivematerial can be a thermally-activated adhesive material, in which theadhesive material is disposed one or both of the undersurface of thelidding body and the upper surface of the peripheral wall, but thelidding body and the container body are not adhered to each other untilthe two bodies are heated and/or activated by a wavelength of light,particularly infrared light. In some embodiments, which may be used incombination with any one or more of the embodiments described above andherein, the adhesive material can be applied as a melt (or thermallysoftened material) to one or both of the undersurface of the liddingbody and the upper surface of the peripheral wall of the container body,or otherwise to a seam defined by the intersection of the lidding bodyand container body.

The thermally-activated adhesive material can be selected from the groupconsisting of water-soluble diluents, water-soluble binders,water-soluble film-formers, and water-soluble gelling agents, includingcombinations thereof, that exhibit sufficient chemical stability duringmelt application or thermally-softened application. Non-limitingexamples of thermally-activated adhesive materials include mannitol,sorbitol, xylitol, lactitol, erythritol, isomalt, povidone, copovidone,hydroxypropylcellulose, a poloxamer, polyethylene glycol, or polyvinylalcohol, or derivatives thereof, and combinations thereof.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, the lidding body issecured to the container body via application of a laser to selectivelymelt, soften, sinter, and/or fuse the material along a seam defined bythe intersection of the lidding body and container body.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, the means forsecuring the lidding body to the container body can comprise a firstmechanical securement on the upper surface of the peripheral wall and asecond mechanical securement on the lidding body, which are mated witheach other to mechanically secure the lidding body to the containerbody. The second mechanical securement can be disposed on theundersurface of the lidding body. The first mechanical securement andthe second mechanical securement can be configured to increase thesurface area of the contact surface between the lidding body and thecontainer body, providing an enhanced frictional engagement and/oradditional surfaces upon which to apply an adhesive material. The firstmechanical securement can comprise one or more valleys formed into theperipheral portion of the upper surface of the peripheral wall, thesecond mechanical securement can comprise one or more peaks formed uponthe peripheral portion of the undersurface of the lidding body, and theone or more peaks of the lidding body are in register with and securedto the one or more valleys of the container body. Alternatively, thefirst mechanical securement can comprise one or more peaks formed uponthe peripheral portion of the upper surface of the peripheral wall, thesecond mechanical securement can comprise one or more valleys formedinto the peripheral portion of the undersurface of the lidding body, andthe one or more peaks of the container body are in register with andsecured to the one or more valleys of the lidding body. In someembodiments, which may be used in combination with any one or more ofthe embodiments described above and herein, an adhesive material canalso be disposed between a portion of the first mechanical securementand the second mechanical securement, as well as between other contactsurfaces between the container body and the lidding body.

The present invention also provides a method for forming arapidly-orodispersible container, which can be utilized to form any ofthe unitary and two-piece dosage forms described above. A method forforming a rapidly-orodispersible container having a cavity forcontaining a medicament or other payload can comprise the steps of:forming a rapidly-orodispersible container base; forming arapidly-orodispersible peripheral wall; and removing the unbound powdermaterial from the filled container, thereby forming therapidly-orodispersible container having a cavity. The method for formingthe container base can comprise the steps of: a) dispensing a powdermaterial into a base powder layer; b) dispensing a binding liquid ontothe base powder layer to form a bound base-matrix layer; and c)optionally repeating steps a) and b) one or more times.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, the method forforming the peripheral wall can comprise the steps of: d) dispersing thepowder material into an intermediate powder layer atop the containerbase; e) dispensing the binding liquid onto a peripheral portion of theintermediate powder layer, without dispersing the binding liquid onto aninterior portion of the intermediate powder layer, to form a filledcontainer consisting of a bound wall-matrix layer that is bound to thecontainer base, and an interior portion consisting of unbound powdermaterial; and f) optionally repeating steps d) and e) one or more times.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, the step of removingthe unbound powder material comprises the sub-steps of: providing avacuum system comprising an air inlet and an air drawing means fordrawing an ambient air into the air inlet; positioning the air inletover the filled container; drawing ambient air into the positioned airinlet to fluidize the unbound powder material within the filledcontainer; and drawing the unbound powder into the air inlet with theambient air. The step of removing the unbound powder material comprisesthe sub-steps of inverting the filled container and decanting theunbound powder material from the filled container. The method forforming the container body can further comprise the steps of: recoveringthe removed unbound powder material using a powder recovery system, andreturning the unbound powder material to a powder reservoir. Therapidly-orodispersible container can be formed into any openthree-dimensional shape with a cavity formed into the shape's topsurface. The rapidly-orodispersible container is in the shape of eitheran open cylinder or an open frustoconical section.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, arapidly-orodispersible unitary dosage form can be formed from any of therapidly-orodispersible containers described above. A method for forminga unitary rapidly-orodispersible dosage form can comprise the steps of:i) forming any of the rapidly-orodispersible containers described above;ii) dispersing one or more payload materials into the cavity; iii)forming an upper layer of powder material over the cavity and the one ormore particulate materials within the cavity, and over the upper surfaceof the container peripheral wall; iv) dispensing a binding liquid onto aportion of the upper layer of powder material, to form a bound-powderupper layer atop the cavity, forming or enclosing the interior cavity;and v) optionally performing steps iii) and iv) one or more times,thereby forming the rapidly-orodispersible dosage form containing apayload material within the cavity. In various embodiments, the payloadmaterial contained within the unitary dosage form comprises one or moremedicaments, and in various embodiments, a solid or particulatemedicament. In various embodiments, the payload material containedwithin the unitary dosage form comprises one or more placebo materials,such as unbound powder material as a non-limiting example. In variousembodiments, the payload material contained within the unitary dosageform comprises one or more solid excipients.

According to the present invention, a one or more solid or particulatepayload material comprises, or consists essentially of, or consists of,a medicament. In some embodiments, which may be used in combination withany one or more of the embodiments described above and herein, the oneor more particulate payload material comprises the medicament and one ormore of any of the excipients described above. The one or moreexcipients can comprise a powder material having the same composition asthe powder material in the bound-powder matrix. In another embodiment,the one or more excipients can consist of a powder material having thesame composition as the powder material in the bound-powder matrix. Inanother embodiment, the payload comprising a medicament can be providedin the form of engineered particles made via spray drying, coating,granulation, chemical complexation, co-crystallization, or combinationsthereof. In some embodiments, which may be used in combination with anyone or more of the embodiments described above and herein, the one ormore particulate payload material can be dispensed into the cavity untilthe cavity is completely filled. In another embodiment, the one or moreparticulate payload material dispensed into the cavity can partiallyfill the cavity. Upon partially filling the cavity with the one or moreparticulate payload material, one or more filler materials can bedispensed into the cavity and atop the payload material until the cavityis filled or completely filled. In an embodiment, the one or more fillermaterials can provide a physical and/or chemical barrier between themedicament or other payload material and the upper layer of powdermaterial that encloses the cavity. The one or more filler materials canbe selected from the group consisting of: calcium carbonate, calciumlactate, calcium phosphate, calcium silicate, calcium sulfate,cellulose, dextrose, erythritol, isomalt, lactitol, lactose, magnesiumcarbonate, magnesium oxide, maltodextrin, maltose, mannitol,microcrystalline cellulose, polyethylene glycol, sodium bicarbonate,sodium carbonate, sodium chloride, sorbitol, starch, sucrose, talctrehalose, and xylitol, including combinations thereof. In anotherembodiment, the filler material can be a superdisintegrant, which can beutilized to enhance the orodispersibility of the dosage form. Asuperdisintegrant can be selected from the group consisting ofcarboxymethylcellulose sodium, croscarmellose sodium, sodium starchglycolate, and crospovidone, including combinations thereof. In anon-limiting example, a cavity partially-filled with a particulatecomposition consisting of, or consisting essentially of, a medicament,can be filled by dispensing a quantity of an unbound powder material,the unbound powder material having the same composition as the powdermaterial in the bound-powder matrix, prior to forming the upper layer ofpowder material over the filled cavity and upper surface of thecontainer peripheral wall.

According to the present invention, a rapidly-orodispersible two-piecedosage form comprising a container body and a lidding body can be formedfrom any of the rapidly-orodispersible containers described above, usinga method comprising the following steps: (a) providing a porous, durablecontainer body made of a first bound-powder material, the container bodyhaving a base, a peripheral wall extending from the base and having aninner surface, an upper surface, and an external surface, the containerbody having one or more cavities bounded by the base and the innersurface of the peripheral wall; (b) providing a porous, durable liddingbody comprising a second bound-powder material; (c) dispensing a solidmedicament or other payload material into the cavity; (d) placing thelidding body onto the upper surface of the peripheral wall, to form aninternal cavity containing the solid medicament or other payloadmaterial; and (e) securing the lidding body to the container body,thereby forming the rapidly-orodispersible dosage form. In variousembodiments, the particulate material contained within the two-piecedosage form comprises one or more medicaments. In various embodiments,the particulate material contained within the two-piece dosage formcomprises one or more placebo materials, such as unbound powder materialas a non-limiting example. In various embodiments, the particulatematerial contained within the two-piece dosage form comprises one ormore solid excipients.

According to the present invention, a method for forming the liddingbody can utilize similar steps as described above for forming acontainer base, namely: dispersing a powder material into a powderlayer; dispensing a binding liquid onto the powder layer to form abound-matrix layer; and optionally repeating the above steps one or moretimes to form the lidding body. The undersurface of the lidding body cancomprise a peripheral portion and an interior portion, the interiorportion including a projection portion, wherein the projection portionextends below the peripheral portion and has an annular outer surface,and when the lidding body is placed onto the upper surface of theperipheral wall, the projection portion extends into a portion of theinterior cavity and the annular outer surface of the projection portionfrictionally engages with a portion of the inner surface of theperipheral wall. The lidding body can have a perimeter wall extendingfrom the peripheral portion of the undersurface, the perimeter wallhaving a bottom surface and an inner surface, wherein when the liddingbody is secured to the container body, the inner surface of theperimeter wall of the lidding body is frictionally engaged with at leasta portion of the external surface of the peripheral wall of thecontainer body. As described above, the inner surface of the perimeterwall of the lidding body can frictionally engaged with the entireexternal surface of the peripheral wall of the container body, in orderto form a planar bottom surface of the rapidly-orodispersible dosageform.

According to the present invention, at least one of the container bodyand the lidding body further comprises an adhesive material, theadhesive material applied to at least a portion of a surface selectedfrom the group consisting of: the upper surface of the peripheral wall;the inner surface of the peripheral wall; the peripheral portion of theundersurface of the lidding body; the annular outer surface of theprojection portion; the external surface of the peripheral wall of thecontainer body; and the inner surface of the perimeter wall, includingcombinations thereof. The step of securing the lidding body comprisesadhering the lidding body to the container body. The adhesive compoundcan be any of the adhesive compounds described above, includingcombinations thereof.

In another embodiment, the step of securing the lidding body to thecontainer body comprises the following sub-steps: forming a firstmechanical securement on the upper surface of the peripheral wall of thecontainer body; and forming a second mechanical securement on thelidding body, wherein the first mechanical securement is configured tomate and frictionally engage with the second mechanical securement tosecure the lidding body mechanically to the container body. The firstmechanical securement and the second mechanical securement can compriseany set of complementary structures that can mate together tomechanically secure the lidding body to the container body. The firstmechanical securement and the second mechanical securement can compriseany combination of peaks and valleys on the underside of the liddingbody and the upper surface of the peripheral wall as described above.The first mechanical securement comprises one or more valleys formedinto the upper surface of the peripheral wall of the container body, thesecond mechanical securement comprises one or more peaks formed into theperipheral portion of the undersurface of the lidding body, at least oneof the one or more valleys and the one or more peaks further comprise anadhesive material applied thereto; and the step of securing the liddingbody to the container body comprises the sub-steps of: mating the one ormore peaks of the lidding body with the one or more valleys of thecontainer body, and adhering the lidding body to the container body.

Thermally-Formed Dosage Forms

In various embodiments, the matrix of in various embodiments of a porousarticle, and in the matrix of other various embodiments, a unitarydosage form or the container body and/or the lidding body of a two-piecedosage form, can substantially be formed without the use or with theminimal use of printing liquids or other solvents, using a thermalmeans. The thermal means can include selective or targeted applicationof heat energy (in a non-limiting example, a directed laser, usingtechniques used in processes such as selective laser sintering orselective laser melting), or bulk techniques such as heating in a mold.In various embodiments, the matrix can be formed by depositing and/orforming a layer of a thermofusable powder material, and to activate thethermofusable powder material into a bound matrix. In some embodiments,the bound matrix can also be described as a granular agglomerate.Methods and apparatuses that utilize a thermofusable powder material toform abound matrix can involve the spreading of the thermofusable powdermaterial into a layer, including over a previous layer or layers, andthe matrices can be formed matrix directly within a dosage form package,such as a blister package, or within a fixed-volume or variable-volumemold cavity.

Where the present description teaches and describes depositing and/orforming a layer of powder material, and subsequently selectively wettingand binding the powder material using a binding liquid, alternativelysuch methods and techniques, and any apparatus and system to depositand/or form the layer of powder material, can be used for forming ordepositing a layer of the thermofusable powder material, and selectivelyactivate the thermofusable powder material to forming a selected portionor portions, or all, of the layer of thermofusable powder material intoone or more portions, or all, of a bound matrix or granular agglomerate.

In one non-limiting example, a method for thermally forming arapidly-orodispersible container having a cavity for containing amedicament or other payload material can comprise the steps of:thermally forming a rapidly-orodispersible container base; thermallyforming a rapidly-orodispersible peripheral wall; and removing theunbound powder material from the formed container, thereby forming therapidly-orodispersible container having a cavity. The method forthermally forming the container base can comprise the steps of: a)dispensing a thermofusable powder material into a base powder layer, thethermofusable powder material comprising a thermal binder; b) applying adirected heat energy onto the base powder layer to thermally activatethe thermal binder, forming a bound base-matrix layer; and c) optionallyrepeating steps a) and b) one or more times on top of the boundbase-matrix layer. In some embodiments, which may be used in combinationwith any one or more of the embodiments described above and herein, themethod for thermally forming the peripheral wall can comprise the stepsof: d) dispersing the thermofusable powder material into an intermediatepowder layer atop the container base; e) applying a directed heat energyonto a peripheral portion of the intermediate powder layer to activatethe thermal binder in the peripheral portion, without applying a heatenergy onto an interior portion of the intermediate powder layer; and f)optionally repeating steps d) and e) one or more times on top of thebound wall-matrix layer, to form a powder-filled container consisting ofa bound wall-matrix layer that is bound to the container base, and aninterior portion containing unbound powder material.

In various embodiments, the thermofusable powder material comprises athermal binder in particle or fibrous form. Once the thermofusablepowder material is disposed within a layer, typically having a uniformthickness, the layer can be heated across its entire surface area, or atpreselected portions of the surface area, in order to soften or melt theparticles of the thermal binder. The heated portion(s) of thethermofusable powder material can form a bound matrix both within andbelow the pre-selected portions of the surface area, while leavingunbound any remaining inactivated thermofusable powder material in aportion or portions of the layer that were not heated.

In various embodiments, particles comprised within a layer ofthermofusable powder material can be selectively joined by exposure tolaser radiation. Laser radiation exposed to pre-determined and selectedareal portions of the layer can melt or liquify (fully or partially) thethermal binder within the thermofusable powder material, bindingtogether the thermofusable powder in such selected portion(s) into abound powder portion of particulate agglomerate. Other areal portions ofthe thermofusable powder that are not exposed to laser radiation can beleft unbound. Afterward, the exposed bound portion(s) are allowed tocool until the melted or softened thermal binder has hardened and/orsolidified, leaving a processed layer of a material that comprisesunbound thermofusable powder in some areal portions, and particulateagglomerate bound by the thermal binder in the remaining areal portions.Alternatively, the entire surface area of a thermofusable powdermaterial layer can be formed into a particulate aggregate. Steps ofspreading a further amount of the thermofusable powder material atop ofa processed layer and exposing the thermofusable powder material tolaser radiation are repeated, layer-by-layer, until the formation of thecontainer body, lidding body, and/or dosage form is complete, thecompleted article consisting of a bound matrix of the particulateagglomerate. In particular, completed containers can consist of one ormore interior cavities, with each interior cavity containing unboundthermofusable powder material.

In various embodiments, the thermofusable powder material comprises amixture comprising one or more thermal binders, at least onecarbohydrate or carbohydrate alcohol, and optionally one or moreexcipients, medicaments and/or payload materials.

In various embodiments, the thermal binder has a glass transitiontemperature at which the thermal binder, and at least the outer surfacethereof, softens and can cohesively contact with adjacent particulatematerial of the thermofusable powder material. In various embodiments,the thermal binder can comprise two or more thermal binders, in whicheach thermal binder can have its own independent glass transitiontemperature, weight, and mean or average particle size distribution. Thebinding capacity for any thermal binder material within a thermofusablepowder material can increase or decrease as a function of its weightcontent, particle size distribution, glass transition temperature, andthe heated temperature to which it is activated. The thermal binder willtypically have a glass transition temperature that is less than a glasstransition temperature of the one or more other particulate componentsof the thermofusable powder material, such as the carbohydrate orcarbohydrate alcohol and one or more excipients, medicaments and/orpayload materials. Preferably the glass transition temperature of thethermal binder is at least 2° C., and more preferably at least 5° C.,lower than that of the other particulate components within thethermofusable powder material. This allows the other particulatecomponents of the thermofusable powder material to remain solid whilethe thermal binder material softens and/or melts, to contact and/orspread into contact with the remaining bulk powder.

In various embodiments, a portion or an entire layer of thermofusablepowder material can be uniformly heated to a staging temperature that isbelow, though typically close to, the glass transition temperature ofany thermal binder contained within the thermofusable powder material.At the staging temperature, the thermal binder material and the otherparticulate components remain solid and free-flowing. By raising thetemperature of a layer of thermofusable powder material, or a portionthereof, to the staging temperature, the intensity and duration of heatapplied by the heat source can be minimized when the heat source isdirected at the pre-selected surface area of the layer of thermofusablepowder material. As a result, the temperature of the thermofusablepowder layer can more efficiently be raised only at pre-selectedportions of the surface area to approach an activating temperature at ornear the glass transition temperature of a thermal binder, while theportions that aren't selected remain at, or near to, the stagingtemperature. Upon reaching the activation temperature, the activatedthermal binder can begin to soften, melt, and cohesively bind toadjacent particulate components in the thermofusable powder materialthat remain solid, in order to form a bound matrix.

In another embodiment, the thermal means can comprise a heat source thatdirects heat energy at the areas to be bonded, while shielding thedelivery of the heat energy at or onto areas of the thermofusable powderlayer that are to remain unbonded and un-agglomerated. Non-limitingexamples of such directing heat energy can include a radiant source,convective heating, radiofrequency heating, sonic heating, or microwaveheating, while a shielding means can include an areal template that isapplied upon to cover the surface of the portion of the layer ofthermofusable powder that is to remain unbound. Templates can becomprised of one or more materials can reflect away or absorb the heatenergy, in order to prevent or greatly restrict its penetrationtherethrough to the powder material beneath.

In various embodiments, a suitable heat source can be directed to heatselected portions or specific planar surfaces of the thermofusablepowder material layer, with high resolution, in order to avoid heatingunintended portions of the powder layer which are to remainun-agglomerated. A non-limiting example of a suitable heat source can bea radiant heater, conductive heating, convective heating, radiofrequencyheating, sonic heating, microwave heating, or laser heating. In variousembodiments, the heat source includes a means for selectively directingthe heat energy for increasing the temperature of the thermofusablepowder material only upon and into the planar portion of the layer ofpowder that is to be thermally bonded, while limiting or preventing theheat energy upon or into the remaining planar portions of the layer ofpowder that are to remain unbonded and un-agglomerated.

In one embodiment, said means can comprise a targeting heat source thattargets heat energy only at the areas of the thermofusable powder layerto be bonded. A non-limiting example of such targeting heat energy is alaser heat source.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a perspective view of a cylindrical rapidly-orodispersibledosage form of the present invention, with a sectional cut-out thatillustrates a medicament contained within an internal cavity of thedosage form.

FIG. 2 illustrates depositing a pile of powder material from a powdersource into a depression.

FIG. 3 illustrates the formation of a first layer of powder materialhaving a substantially-uniform thickness.

FIG. 4 illustrates the application of a printing liquid onto thesubstantially-uniform first layer of powder material, to form a wettedpowder layer.

FIG. 5 illustrates the application of a printing liquid at peripheralportions of a second substantially-uniform layer of powder material, toform a second incremental layer having a wetted peripheral portion and acentral, unwetted portion.

FIG. 6 illustrates an example of a container formed within a depression,the container having a base, a peripheral wall, and a central cavityfilled with unwetted, unbound powder.

FIG. 7 shows a top plan view of exemplary substantially-uniform widthsof the peripherally-bound portion of an incremental layer forming theperipheral wall of the container.

FIG. 8 shows a perspective view of a container having two cavities.

FIG. 9 shows a perspective view of a container having three cavities.

FIG. 10 illustrates the application of a vacuum by a vacuum apparatuspositioned within a cavity and evacuating unwetted/unbound powder fromthe container.

FIG. 11 illustrates a vacuum pipette that can be lowered into theunbound powder of a container, and maneuvered circumferentially andradially within the cavity to evacuate the unbound powder.

FIG. 12 illustrates the operation of a vacuuming system within aventilated hood, illustrating the generation of a turbulent airflow overthe container having a central portion of unwetted/unbound powder.

FIG. 13 illustrates a complete filling on the left side, L, andalternatively a partial filling on the right side, R, of the emptycavity of the container, with one or more solid medicaments.

FIG. 14 illustrates the complete filling of the partially-filled cavityshown in the right side of FIG. 13 , by depositing one or more fillermaterials on top of the one or more solid medicaments already inside thecavity.

FIG. 15 illustrates on the left side, L, the formation of an uppersubstantially-uniform layer of powder material on top of thecavity-filling medicament, and on the right side, R, the application ofa printing liquid onto the upper substantially-uniform layer of powder.

FIG. 16 illustrates on the left side, L, the formation of an upper boundmatrix layer enclosing the cavity-filling medicament, to form therapidly-orodispersible dosage form, and on the right side, R, theapplication of a lidding film over the dosage-form filled depression toform the dosage form product.

FIGS. 17-21 illustrate forming, filling and sealing a unitary,partially-enclosed dosage form having an internal cavity, formed withina depression of a packaging. FIG. 17 shows a sectional view of acontainer body formed within a depression as shown in FIG. 6 , on whichone (or more) incremental layer of powder material is deposited.

FIG. 18 illustrates the forming, for example with a binding liquid, alid for the container body having an area of unbound powder material toform a port opening, and the container body having an internal cavityfilled with unbound powder material.

FIG. 19 shows a sectional view of the formed unitary, partially-encloseddosage form of FIG. 18 with the unbound powder material being evacuatedfrom the cavity through the port opening in the lid.

FIG. 20 shows a means for partially or completely filling the emptycavity of the container body of FIG. 18 , through the port opening inthe lid, with a payload material.

FIG. 21 shows the closing and sealing of port opening in the lid, toform the filled-and-sealed dosage form having a cavity containing thepayload material.

FIG. 22 shows an exploded view of an elongated container body having acircular upper surface and an elongated lidding body having a circularundersurface that is the same size as the upper surface of the containerbody.

FIG. 23 shows a perspective view of a spherocylindrical, two-piecedosage form assembled from the container body and lidding body of FIG.22 .

FIG. 24 shows an exploded view of a container body having an ellipticalupper surface and a lidding body having an elliptical undersurface thatis the same size as the upper surface of the container body.

FIG. 25 shows a perspective view of an ovoid, two-piece dosage formassembled from the container body and lidding body of FIG. 24 .

FIG. 26 shows an exploded view of a container body having a rectangularupper surface and a lidding body having a rectangular undersurface thatis the same size as the upper surface of the container body.

FIG. 27 shows a perspective view of a cuboid, two-piece dosage formassembled from the container body and lidding body of FIG. 26 .

FIG. 28 shows an exploded perspective view of a cylindrical, two-piecedosage form having a container body and an upper lidding body.

FIG. 29 shows an exploded perspective view of another cylindrical,two-piece dosage form, in which the lidding body has an interiorprojection portion extending from the undersurface of the upper liddingbody.

FIG. 30 shows a perspective view of an alternate embodiment of a dosageform having a plurality of peaks extending from the undersurface of thelidding body and a plurality of complementary valleys formed into theupper surface of the container body.

FIG. 31 shows a perspective view of a dosage form assembled by securingthe lidding body and container body of FIG. 29 .

FIG. 32 shows an exploded perspective view of an alternate embodiment ofa lidding body and a container body, the lidding body having a perimeterwall extending from a peripheral portion of the lidding bodyundersurface and radially beyond the perimeter wall of the containerbody.

FIG. 33 shows a perspective view of a dosage form assembled by placingthe lidding body of FIG. 32 over the container body.

FIG. 34 shows an exploded perspective view of an alternate embodiment ofa lidding body and a container body, the lidding body having a trio ofpins extending from an undersurface of the lidding body, to engage acorresponding trio of slots in the peripheral wall of the containerbody.

FIG. 35 shows an exploded perspective view of another alternateembodiment of a lidding body and a container body, the lidding bodyhaving a pair of opposed pins extending from an outer peripheral surfaceof the lidding body, to engage a correspondingly-shaped pair of slots inthe upper surface of the peripheral wall of the container body.

FIG. 36 shows a perspective view of a dosage form assembled by placingthe lidding body of FIG. 35 over the container body.

FIG. 37 shows an exploded perspective view of an alternate embodiment ofa lidding body and a container body, the lidding body having a pair ofkeystone slots in a perimeter wall of the lidding body, to engage a pairof keystone pins atop the peripheral wall of the container body.

FIG. 38 shows the lidding body being assembled to the container body onFIG. 37 by engaging the keystone pins in the container body into thekeystone slots in the lidding body.

FIG. 39 shows a lidding body having a tapered thread segment thatengages a matching tapered slot segment of a container body, forengaging the lidding body to the container body by a threading action.

FIGS. 40-46 illustrate the forming of a plurality of container bodieswithin an open print bed. FIG. 40 shows an open print bed apparatus,with a build plate superposed on a height-adjustable platform.

FIG. 41 shows the processing of dosage forms in a first series of steps,for forming a plurality of bases for the container bodies, by loweringthe build plate to provide a cavity, placing a layer of powder withinthe cavity upon the upper surface of the build plate, and depositing abinding liquid onto selected portions of the powder layer to form aplurality of bases consisting of the bound powder matrix.

FIG. 42 shows the processing of dosage forms in a second series ofsteps, for forming a plurality of peripheral walls for the containerbodies, by lowering the build plate to provide a cavity, placing a layerof powder within the cavity upon the previous layer of unbound powderand bound powder bases, depositing a binding liquid onto selectedportions of the powder layer to form a plurality of peripheral wallsconsisting of the bound powder matrix, upon the plurality of bases.

FIG. 43 shows the processing of dosage forms in a third series of steps,for completing the plurality of peripheral walls for the containerbodies, by lowering the build plate to provide a cavity, placing a layerof powder within the cavity upon the previous layer of unbound powderand bound-powder peripheral walls, depositing a binding liquid ontoselected portions of the powder layer to form a plurality of upperportions of the peripheral walls consisting of the bound powder matrix.

FIG. 44 shows the processing of dosage forms in a fourth series ofsteps, for evacuating the unbound powder from within the peripheralwalls of the container bodies, and depositing a particulate payloadmaterial to fill the evacuated container bodies.

FIG. 45 shows the processing of dosage forms in a fifth series of steps,for forming a plurality of container tops for the filled containerbodies, by lowering the build plate to provide a cavity, placing a layerof powder within the cavity upon the previous layer of unbound powderand filled container bodies, depositing a binding liquid onto selectedportions of the powder layer to form a plurality of container topsconsisting of the bound powder matrix, upon the plurality of filledcontainer bodies, to form a plurality of dosage forms.

FIG. 46 shows an alternative process for evacuating the unbound powderfrom within the peripheral walls of the container bodies, and depositinga particulate payload material to fill the evacuated container bodies.

FIG. 47 shows an alternative process for forming a plurality ofcontainer bodies in a series of steps with the bottom side up, byforming in one or more layers an upper portion of a plurality ofperipheral wall portions, then forming in one or more layers theremaining peripheral wall portions, and then forming a plurality ofbases consisting of the bound powder matrix, upon the peripheral wallportions, to form the plurality of dosage container bodies.

FIG. 48 shows a top plan view of an exemplary arrangement of a pluralityof containers formed within an open print bed of a 3DP equipmentassembly.

FIGS. 49-54 illustrate forming, filling and sealing a unitary,partially-enclosed dosage form having an internal cavity, formed in anopen print bed of a 3DP equipment assembly. FIG. 49 shows a sectionalview of a container body formed from a plurality of incremental layersof build powder material, having a base and a peripheral wall, with anopen cavity bounded by the peripheral wall that is filled with the buildpowder material. A plurality of the container bodies being processed inan open print bed is shown in FIG. 43 at step D3.

In the present embodiment, as illustrated in FIG. 50 , the build plate306 is lowered an incremental distance, and one (or more) substantiallyuniform, incremental layer of build powder material is applied over theformed container body and build powder material, and an area on theupper surface of the build powder layer illustrates where a printingliquid will be directed.

FIG. 51 shows a sectional view of the formed unitary, partially-encloseddosage form having an internal cavity filled with unbound powdermaterial, and a top lid formed from the selected printing of the layerof build powder material, the top lid having a port opening formed fromunwetted and unbound build powder.

FIG. 52 shows the use of an evacuation system to remove the unboundpowder material from within the cavity through the port opening.

FIG. 53 shows a means for partially or completely filling the emptycavity of the partially-enclosed dosage form with a payload material.

FIG. 54 shows the closing and sealing of port opening in the lid, toform the filled-and-sealed dosage form.

FIG. 55 shows an alternative embodiment of a unitary, partially-encloseddosage form with a port opening formed in a peripheral wall of thecontainer body.

FIG. 56 shows the unitary, partially-enclosed dosage form of FIG. 55being filled with a payload through the port opening in the peripheralwall of the container body.

FIGS. 57-60 illustrate the forming, filling and sealing of analternative embodiment of a unitary dosage form having an internalcavity and port opening in a peripheral wall of the container body. FIG.57 shows a sectional view of a container body formed from a plurality ofincremental layers of build powder material, having a base and aperipheral wall, and one (or more) substantially uniform, incrementallayer of build powder material is applied over the formed container bodyand build powder material. A plurality of the container bodies beingprocessed in an open print bed is shown in FIG. 43 at step D3.

FIG. 58 illustrates a unitary top formed onto the container body byprinting the build powder layer, enclosing unwetted build powder withinthe internal cavity of the container body.

FIG. 59 illustrates forming a port opening into the peripheral side wallwith a boring means, and a means for evacuating the unwetted buildpowder from within the cavity.

FIG. 60 shows a finished dosage article following the deposit of apayload material through the port opening and into the internal cavityof the dosage form, and sealing of the port opening.

FIG. 61 illustrates on the left side, L, a first layer of athermofusable powder material formed within the base of a depression ofa dosage form package, and on the right side, R, heat energy directedacross the entire surface of the first layer to form a stabilizedgranular agglomerate of a thermofused first layer.

FIG. 62 illustrates on the left side, L, a second layer of thethermofusable powder material onto the thermofused first layer, and onthe right side, R, the heat energy targeted at a peripheral portion ofthe second layer of powder, forming the selected peripheral portion intoa stabilized granular agglomerate, while the remaining central portionof the second layer remains unbonded.

FIG. 63 illustrates on the left side, L, a third layer of thethermofusable powder material onto the thermofused second layer, and onthe right side, R, the heat energy targeted at a peripheral portion ofthe third layer of powder, forming the selected peripheral portion intoa stabilized granular agglomerate, while the remaining central portionof the third layer remains unbonded.

FIG. 64 illustrates a partially thermofused article with five completedlayers, with the fourth and fifth layers formed substantially as thethird layer, where on the left side, L, a sixth layer of thethermofusable powder material is formed onto the thermofused fifthlayer, and on the right side, R, the heat energy targeted at aperipheral portion of the sixth layer of powder, forming the selectedperipheral portion into a stabilized granular agglomerate, while theremaining central portion of the six layer remains unbonded.

FIG. 65 illustrates on the left side, L, the partially-formed containerof FIG. 45 , with a vacuum system withdrawing the unbound thermofusablepowder out of the central portion, to leave an empty cavity, and on theright side, R, a complete filling of the empty cavity with a particulatemedicament.

FIG. 66 illustrates on the left side, L, a top layer of a thermofusablepowder material onto the upper surface of the peripheral thermofusedportion of the sixth layer and the central portion-filling medicament,and on the right side, R, heat energy directed across the entire surfaceof the first layer to form a stabilized granular agglomerate of athermofused first layer, enclosing the medicament within the cavity ofthe stabilized granular agglomerate of the dosage form.

FIGS. 67 and 68 illustrate selected steps in a process for forming of aplurality of container bodies within an open print bed of a 3DPequipment assembly, by placing a layer of thermofusable powder withinthe upper surface of the open print bed, and directing heat energyacross the selected portions of the surface of the layer for increasingthe temperature of the thermofusable powder material, and formingthermofused layer portions, and shielding the delivery of the heatenergy at or onto areas of the thermofusable powder layer that are toremain unbonded and un-agglomerated.

FIG. 69 shows a first embodiment of a shield for allowing heat energy topass through openings to form uniform circular patterns.

FIG. 70 shows a second embodiment of a shield for allowing heat energyto pass through openings to form annular or ring patterns.

DETAILED DESCRIPTION OF THE INVENTION Definitions

As used herein, the terms “cavity” and “internal cavity,” with respectto a dosage form, interchangeably refer to a compartment or void that isconfigured for containing and isolating one or more solid materials,particularly one or more medicaments, within any of the dosage forms ofthe present invention, bound by the container base and an inner surfaceof the dosage form's peripheral wall. The term “cavity” can also referto a cavity with an open top surface for receiving solid materials intothe cavity, while the term “internal cavity” can refer to the cavityafter it has been enclosed to from the rapidly-orodispersible dosageform.

As used herein, the term “unitary”, with respect to a dosage form,refers to a dosage form having a single, seamless bound matrix havingtwo or more elements that surround and enclose an interior cavity, forexample, a base portion, peripheral walls, and a lid portion, as opposedto a two-piece dosage form having a separated container body and a lidthat are secured together.

As used herein, the term “3DP” is an abbreviation referring to either“three-dimensional printing,” “three-dimensionally printed,” or othersuch conjugation thereof.

As used herein, the term “tamping” pertains to an act of reducing theporosity or pore volume within a volume of a mass of powder under aforce that reduces the volume of the mass of powder. Tamping can beperformed with a tamper system, whereby a volume of one or moreincrementally-formed layer of powder, particularly within a depression,is shaped and/or reduced.

As used herein, the term “depression,” with respect to a packaging,refers to a spatial cavity formed into a portion of a packaging for adosage form. Non-limiting examples of the depression portion of apackaging include a blister, cup, pod, or other packaging receptaclecapable of receiving and containing flowable materials such as powder orliquid.

As used herein, the term “pharmaceutically acceptable” refers to thosecompounds, materials, compositions, and/or dosage forms which are,within the scope of sound medical judgment, suitable for use in contactwith tissues of human beings and animals and without excessive toxicity,irritation, allergic response, or any other problem or complication,commensurate with a reasonable benefit/risk ratio.

As used herein, the term “derivative” refers to either a) a chemicalsubstance that is related structurally to a first chemical substance andtheoretically derivable from it; b) a compound that is formed from asimilar first compound or a compound that can be imagined to arise fromanother first compound, if one atom of the first compound is replacedwith another atom or group of atoms;

c) a compound derived or obtained from a parent compound and containingessential elements of the parent compound; or d) a chemical compoundthat may be produced from first compound of similar structure in one ormore steps.

As used herein, the term “orodispersible” refers to dosage forms thatcan disperse or disintegrate in the mouth in a minimal amount of salivaor water. The term “rapidly-orodispersible” refers to dosage forms takecan disperse or disintegrate in the mouth in a minimal amount of salivaor water in 90 seconds or less.

As used herein, the term “shaping,” with respect to a 3DP-buildingprocess, refers to the act of altering the shape of one or more surfacesof an incremental layer of a material, or the shape of a plurality ofone or multiple layers. The altering of the shape can be of the entiresurface or of only a portion of the surface, and typically the uppersurface at the step of shaping. The altered shape can be flat or planar,convex, concave, or any other shape as desired. The altered shape of theupper surface can be different from the shape of the lower surface.

As used herein, the term, “three-dimensional printing build system” or“3DP build system” generally comprises a powder layering system(region), where a powder material is deposited and/or layered into anincremental powder layer, and then powder material is formed selectivelyinto one or more bound-powder matrix(cies). In one non-limiting example,the bound powder matrix(cies) is formed with a printing system (region),wherein a binding liquid is applied as the printing liquid to theincremental powder layer according to a pre-determined pattern therebyforming a partially- or fully bound-powder layer (an incremental printedlayer) comprising the bound powder matrix(cies).

Embodiments of the Invention

A non-limiting example of a rapidly-orodispersible dosage form accordingto the present invention is illustrated in FIG. 1 . As shown in FIG. 1 ,the dosage form 1 has a cylindrical shape and comprises a lower portion2 having a base 3, an upper portion 4 having a top surface 5, and anannular peripheral wall 6. The dosage form has an interior cavity thatis filled with an unbound, solid medicament M and is circumferentiallybound by an inner surface of the peripheral wall 6. The lower portion 2,upper portion 4, and the annular peripheral wall 6 comprise a single,interconnected and unitary matrix that encloses and isolates theinterior cavity within the dosage form 1.

In various embodiments, the interconnected matrix can consist ofadjacent particles of the powder material that are connected and bondedtogether by a binder material that can bind to the particles of thepowder material and to other binder material.

In various embodiments, a dosage form illustrated in FIG. 1 can beformed using an additive manufacturing apparatus, system and process.One non-limiting example of an additive manufacturing process, andassociated apparatus and system, is a three-dimensional printing (3DP)building process. Generally, 3DP systems include a powder layeringsystem that forms a layer of build powder, and a printing system thatapplies a printing liquid, typically containing a binder material, tothe layer of build powder according to a pre-determined pattern, therebybinding the build powder and forming a printed or bound-powder layer. Aheight adjustable platform can be utilized in cooperation with thepowder layering system to form incremental printed layers one on top ofanother to vertically build the dosage form of the invention, therebyforming an article comprising a plurality of incrementally-printedlayers. In another embodiment, the number of printed incremental layerscan be in a range from at least 3 layers and up to at least 50 layers,or from at least 10 layers up to 50 layers, or from at least 15 layersup to at least 45 layers, or from at least 20 layers up to at least 40layers, or from at least 5 layers up to at least 15 layers, or from atleast 5 layers up to at least 10 layers.

The process of spreading powder and depositing droplets of the printingliquid is repeated until the desired number of layers for the article iscomplete. The layers adhere to one another due to infiltration of theprinting liquid from one layer to an adjacent other layer such that thepowder material in one incremental layer can adhere to adjacent,previously-formed incremental layers. Following completion of theinitial three-dimensional structure, residual binding liquid can beremoved from or reduced in the article by a drying process. Theevaporation of solvent during the drying process results in a boundmatrix having a three-dimensional architecture comprising the particlesof the bound-powder material and a binder material. The physicalproperties of the resulting dosage forms, such properties includinghardness, bulk density, disintegration time, dissolution time,bioavailability, moisture content, mouthfeel and friability, can begenerally controlled by selectively varying incremental powder layerthickness, powder composition, printing fluid composition, printingfluid saturation level on a layer, and identity and amount of theexcipients included within the dosage form, non-limiting examples ofwhich include the identity and amount of disintegrant, binder,sweetener, surfactant. Additionally, the identity, amount, and physicalform of the API compound or medicament can also have an effect, asdescribed in further detail below.

According to various embodiments described herein, an example of anotherrapidly-orodispersible dosage form according to the present invention isillustrated in FIG. 16 , and is described in more details herein after.

With respect to a dosage form, and a rapidly-orodispersible dosage formin particular, in a non-limiting example, FIG. 2 illustrates a step ofdepositing a first pre-determined amount of a powder material 9comprising particles, within a blister pack depression 10 formed into asheet 11 of a film or laminate material. As a non-limiting example,blister pack depressions can be formed using conventional cold-formingor thermoforming processes. The depression 10 has a closed end 12 and anouter wall 13 that forms a boundary for a space 14 within the depression10. The powder material 9 is discharged from a feed container or hopper,through a powder-dosing apparatus (not shown). Typically, thepowder-dosing apparatus is designed and configured to dispense apre-determined amount of powder material 9 from the feed container,which can include a pre-determined volumetric amount of powder material9 or a predetermined mass amount of powder material 9. In theillustrated embodiment, a pre-determined amount of powder material 9 isdeposited onto the closed end 12 of the depression 10 in the form of apile 15 of powder material 9. In an embodiment, the predetermined amountof powder material 9 can be a pre-determined volume of a powdermaterial, the powder material 9 having presumably a substantiallyuniform powder density such that the pre-determined volume delivers asubstantially fixed mass weight of the powder material 9. In anotherembodiment, the pre-determined amount of powder material 9 can be apre-determined mass weight of a powder material. Again, presuming asubstantially uniform powder density, the pre-determined mass weightdelivers a substantially fixed volume of the powder material 9. In theillustrated embodiment, the pre-determined mass weight of a powdermaterial 9 provides a volume of powder material 9 sufficient to form asubstantially-uniform powder layer of the fixed volume, within thebottom portion of the space 14 within the depression 10. In anotherembodiment, the pre-determined amount of powder material 9 can bemechanically dosed and/or metered into the depression 10 by any meansknown in the art, non-limiting examples of which are described in U.S.Pat. Nos. 9,409,699 and 9,828,119, US Patent Publications 2017/0322068and 2018/0031410, and U.S. Patent Application No. 62/745,750, thedisclosures of which are incorporated by reference in their entireties.Another non-limiting example of a mechanical dosing and/or meteringapparatus can include a gravimetric powder dispensing/powder dosingapparatus available from ChemSpeed Technologies(https://www.chemspeed.com/flex-powderdose/), the disclosure of which isincorporated by reference in its entirety.

Upon dispersing a pre-determined amount of a powder material 9 into thedepression 10, the powder material 9 can be formed into a base powderlayer having a substantially uniform thickness, as shown in FIG. 3 , byany leveling means known in the art. Non-limiting examples of suchleveling means include: tamping; oscillation laterally, orbitally,and/or vertically; vibration; brushing; and vacuuming. In particular,U.S. Pat. No. 10,071,372 and U.S. Patent Publication 2017/0312179, thedisclosures of which are incorporated herein by reference in theirentireties, describe a system that both dispenses a predetermined amountof the powder material 9 and subsequently forms the powder material 9into a substantially uniform layer. In an embodiment, the leveling meanscan be a tamping system, a non-limiting example of which is described inU.S. Patent Application No. 62/745,750, above. The tamping system canuse a tamper with an undersurface that contacts with a pile 15 of powdermaterial 9 to form a uniform powder layer having a substantially uniformthickness, t, as shown in FIG. 3 . The tamper can be used to form anincremental layer with a substantially uniform thickness and/or tocompress the plurality of layers of the printed dosage form, asdescribed in further detail below.

In another embodiment, the substantial uniform thickness of the basepowder layer 20, or any of the successive incremental powder layersdiscussed in further detail below, can have a predetermined height in arange from at least 0.005 inches, up to 0.1 inches; or at least 0.01inches, up to 0.08 inches; or at least 0.02 inches, up to 0.06 inches;or at least 0.03 inches, up to 0.05 inches; or at least 0.025 inches, upto about 0.05 inches. In another embodiment, the substantial uniformthickness of any of the powder layers can be in a range from at least0.1 mm, up to 2.5 mm; or at least 0.5 mm, up to 2.0 mm; or at least 0.5mm, up to 1.5 mm; or at least 1 mm, up to 1.5 mm; or at least 0.75 mm,up to 1.25 mm. In another embodiment, the substantial uniform thicknessof any of the powder layers can be in a range from at least about 100microns to about 500 microns, or from at least about 100 microns toabout 400 microns, or from at least about 100 microns to about 300microns.

Without being limited by a particular theory, as thicker incrementallayers are used, an increasing amount of binding liquid can be depositedto ensure adequate binding both within the plane or thickness of thelayer, and from layer-to-layer, and specifically from the powder layerbeing bound and the previously-formed bound-powder layer below.Conversely, for a thinner incremental layer a lesser amount of bindingliquid can be deposited to obtain the same extent of binding. For agiven amount of binding liquid deposited per layer, using a larger layerthickness can reduce (worsen) handleability of the dosage form, butreduce (improve) dispersion time. If a layer is too thick relative to agiven amount of liquid, laminar defects may form and cause the dosageform to fracture along the planar interface of the layers(delamination), or the dosage form itself may not have adequate strengthto be handled at all.

In another embodiment, the base powder layer 20, or any of thesuccessive incremental powder layers discussed in further detail below,can have a pre-determined mass of deposited powder material, based inpart on the desired thickness of the bound-powder layer. In anotherembodiment, the amount of the dispensed powder material to form thebound-powder layer can be in a range from at least 1 mg and up to 1 g;or at least 10 mg and up to 500 mg; or at least 25 mg and up to 300 mg;or at least 50 mg and up to 250 mg; or at least 100 mg and up to 200 mg;or at least 125 mg and up to 175 mg.

FIG. 4 shows, in the left side of the illustration, a step of applying abinding liquid onto a substantially uniform base powder layer 20. Invarious embodiments, the binding liquid contains (comprises) a bindermaterial, or the build powder contains (comprises) a particulate bindermaterial, or both the binding liquid and the build powder contain(comprise) a binder material. The binding liquid can be applied as aprinting liquid using 3DP methods and systems, such as those describedin U.S. Pat. Nos. 6,471,992, 6,945,638, 7,300,668, 7,875,290, 8,088,415,and 8,888,480, the disclosures of which are incorporated by reference intheir entireties. Printing liquid can be dispensed in drops or in fluidunits resembling drops. Either the printhead, the substrate, or both,may move to facilitate deposition of droplets. Drops can be dispensed ina succession that forms a line corresponding to the relative motion ormovement of the printhead nozzle and the substrate. The spacing betweenthose drops is the drop-to-drop spacing, which is a function of thedroplet dispensing rate from the nozzle and the relative rate ofmovement of the nozzle and the substrate. After completion of one line,another line may be deposited adjacent to the earlier-deposited line andseparated from the earlier-deposited line by a distance that is aline-to-line spacing. In various embodiments, drops may be dispensedfrom a plurality of spaced-apart printing nozzles, arranged into one ormore rows, and in a succession that forms a row line of dropscorresponding to the motion of the printhead, wherein thenozzle-to-nozzle spacing results in a line of drops having adrop-to-drop spacing. Drops can be dispensed in a succession from eachof the nozzles that forms a column line of drops corresponding to amotion or movement of the printhead nozzle transverse to the row ofnozzles of the printhead. The spacing between those drops is aline-to-line spacing, which is a function of the droplet dispensing ratefrom the nozzle and the rate of transverse movement of the printhead.

In FIG. 4 , a first predetermined quantity of printing liquid isdeposited by dispensing droplets 21 of the binding liquid from the printnozzles 23 of an inkjet printing nozzle assembly 22. The binding liquidcan be dispensed across an entire surface of the substantially uniformbase powder layer 20. In embodiments in which the printing liquid is abinding liquid comprising a binding material, the droplets 21 of bindingliquid bind particles of the substantially uniform base powder layer 20into a cohesive powder-liquid matrix, forming a substantially-uniformfirst layer of wetted powder 24, shown in the right side of theillustration of FIG. 4 . In a typical embodiment, the binding liquidincludes an amount of a solvent that remains in excess in the resultingwetted powder layer, and is preferably removed to form a finishedbound-powder layer. In another embodiment, excess solvent can beevaporated off of the bound-powder layer by heating or irradiating thelayer with infrared radiation, for example as described in U.S. Pat.Nos. 6,990,748, 6,047,484, and 4,631,837, the disclosures of which areincorporated herein by reference in their entireties.

In another embodiment, the build powder material can be a bulk powdercomprising a plurality of particulate components. In another embodiment,one or more of the plurality of particulate components can include oneor more pharmaceutically acceptable excipients, selected from the groupconsisting of: disintegrants, particulate binder materials, surfactants,glidants, sweeteners, flavorants, humectants, antioxidants,preservatives, and diluents, including combinations thereof. In anotherembodiment, the one or more pharmaceutically acceptable excipients canalso be dissolved, suspended, or otherwise comprised within the bindingliquid. Each excipient may be independently selected from the groupconsisting of a water-soluble, aqueous-fluid soluble, partially-watersoluble, partially-aqueous-fluid soluble, water-insoluble oraqueous-fluid insoluble excipient, as needed, to provide the desiredparticle-to-particle binding properties within the printed matrix. Mostpharmaceutically acceptable excipients, both small molecules andpolymers, can be employed to support the activity or stability of themedicaments and/or to facilitate the rapid dispersion of the dosage formin the presence of an appropriate aqueous fluid, for example, water orsaliva. Some of these excipients, suitable for use in thethree-dimensional printing process of the invention, are listed in theHandbook of Pharmaceutical Excipients (Eds. A. Wade and P. J. Weller,Second edition, American Pharmaceutical Association, The PharmaceuticalPress, London, 1994).

In another embodiment, one or more disintegrants can be comprised withinthe bulk powder. The use and identity of a particular disintegrant canbe independently selected upon each occurrence, dependent on desireddispersion properties of the dosage form. In another embodiment, thebulk powder can comprise disintegrant in a weight range, by weight ofthe bulk powder, of at least 5% and up to 30%; or at least 10% and up to25%; or at least 15% and up to 25%; or at least 18% and up to 24%; or atleast 18% and up to 23.7%; or at least 1% and up to 30%; or at least 1%and up to 25%; or at least 20% and up to 25%. In another embodiment, adisintegrant can be selected from the group consisting of:microcrystalline cellulose, crospovidone (cross-linkedpolyvinylpyrrolidone), croscarmellose, or sodium starch glycolate,including combinations thereof. In another embodiment, the disintegrantcan be microcrystalline cellulose, including one or more grades ofAVICEL® microcrystalline cellulose, available from Sigma-Aldrich.

In an embodiment, one or more binder materials can be comprised withinthe bulk powder or within the binding liquid. The binder material can beindependently selected upon each occurrence. Adhesion of the particlesto and/or by the binder material occurs either when the binder materialis contacted by the binding liquid from the printhead or when it ispresent in the binding liquid itself as a binding liquid. The bindermaterial is preferably water soluble, aqueous fluid soluble, partiallywater soluble or partially aqueous fluid soluble. The binding liquid cancomprise binder material in a weight range, by weight of the bindingliquid, of at least 1% and up to 20%; or at least 5% and up to 15%; orat least 8% and up to 12%. In some embodiments, the bulk powdercomprises up to 15%, for example, up to 10% by weight, of a bindermaterial. In another embodiment, the bulk powder comprises bindermaterial in a weight range, by weight of the bulk powder, of at least 5%and up to 15%; or at least 8% and up to 14%; or at least 9% and up to11%. In another embodiment, the printed dosage form can comprise bindermaterial in a weight range, by weight of the dosage form, of at least 1%and up to 20%; or at least 5% and up to 14%; or at least 8% and up to12%. The binder material is present in the binding liquid only, in thebulk powder only, or in both the binding liquid and the bulk powder.

In an embodiment, binder materials can be selected from the groupconsisting of water-soluble synthetic polymer, polyvinylpyrrolidone(povidone), sorbitol, mannitiol, xylitol, lactitol, erythritol,pregelatinized starch, modified starch, hydroxypropylmethylcellulose andothers. The preferred binder is polyvinylpyrrolidone, e.g., PVP K30,modified starch (e.g., starch sodium octenylsuccinate), mannitol or acombination thereof. PVP with a K value different from 30 may be used,including without limitation PVP K25 and PVP K90. Spray dried lactose,fructose, sucrose, dextrose, sorbitol, mannitol, or xylitol can also beutilized as binder materials, although they generally exhibitlow-strength binding properties in many applications.

Without being limited by a particular theory, the presence, identity,and concentration of binding materials and disintegrants can influencethe hardness, friability, and dispersion time of the dosage form.Generally, the greater the amount of a binder material that is presentin the dosage form, the higher the hardness, the lower the friabilityand the slower the dispersion time. On the other hand, increasing theamount of disintegrant generally provides lower hardness, increasedfriability and a faster dispersion time. Accordingly, in anotherembodiment, the rapidly orodispersive dosage form of the inventioncomprises a balanced amount of binder and disintegrant, depending on thedesired hardness, friability and dispersion time of the dosage form.

In some embodiments, which may be used in combination with any one ormore of the embodiments described above and herein, one or moresweeteners can be comprised within the bulk powder or within the bindingliquid. Taste-masking of the solid medicament or other excipients can beachieved when at least one sweetener is present in at least the bindingliquid, and preferably, both the binding liquid and the bulk powder. Thepresence and identity of a sweetener can be independently selected uponeach occurrence. In another embodiment, the binding liquid and the bulkpowder can have at least one sweetener in common, such as, in anon-limiting example, when the binding liquid and bulk powder eachcomprise the same sweetener and the bulk powder comprises an additionalsweetener. In another embodiment, the bulk powder comprises up to 5% byweight of sweetener, or up to 2% by weight of sweetener, or up to 1.5%by weight of sweetener. In another embodiments, the binding liquidcomprises up to 5% sweetener, or comprises sweetener in a range from atleast 0.5% be weight, up to 4% by weight; or at least 1% by weight, upto 3% by weight of the binding liquid.

In an embodiment, sweeteners can be selected from the group consistingof a glycyrrhizinic acid derivative, such as, in a non-limiting example,Magnasweet® (monoammonium glycyrrhizinate), sodium saccharin, sucrose,stevia, sucralose, aspartame, acesulfame potassium, and neotame,including combinations thereof. In another embodiment, sucralose can beincluded within the binding liquid. In another embodiment, a sweeteneris included within the binding liquid. In another embodiment, asweetener is included within both the binding liquid and the bulkpowder. In another embodiment, a sweetener may be selected from thegroup consisting of acesulfame potassium, alitame, ammoniumglycyrrhizate, aspartame, compressible sugar, confectioner's sugar, cornsyrup solids, dextrose, dextrose anhydrous, erythritol, fructose,galactose, glycerin, glycine, glycyrrhizin, inulin, isomalt, lactitol,liquid glucose, maltitol, maltitol solution, maltose, mannitol,D-mannose, neohesperidin dihydrochalcone, neotame, saccharin, saccharinsodium, sodium cyclamate, sorbitol, sucralose, sucrose, tagatose,thaumatin, trehalose, and xylitol.

In an embodiment, one or more flavorants can be comprised within thebulk powder or within the binding liquid. The presence and identity of aflavorant can be independently selected upon each occurrence. In anotherembodiment, the flavorant is water soluble, aqueous-fluid soluble,partially-water soluble, or partially-aqueous-fluid soluble. The bindingliquid comprises can comprise a flavorant in a range of at least 0.01%by weight, and up to 5% by weight; or at least 0.1% by weight, and up to1% by weight; or at least 0.2% by weight, and up to 0.5% by weight ofthe binding liquid. The flavorant may be provided on a powdered carrier.The carrier can be chosen from the group consisting of: starches,celluloses, and other excipients within which the flavorant could beabsorbed, adsorbed, encapsulated, or otherwise loaded, includingcombinations thereof. In another embodiment, the bulk powder cancomprise a flavorant-loaded carrier in a range from at least 0.1% byweight, and up to 10% by weight; or at least 1% by weight, and up to 9%by weight; or at least 2% by weight, and up to 8% by weight of the bulkpowder. The dosage form can comprise a flavorant-loaded carrier in arange from at least 0.1% by weight, and up to 10% by weight; or at least1% by weight, and up to 9% by weight; or at least 2% by weight, and upto 8% by weight of the dosage form. A flavorant can be included withinthe binding liquid only, within the bulk powder only, or within both thebinding liquid and the bulk powder.

In another embodiment, the one or more flavorants can be selected fromthe group consisting of spearmint, peppermint, mint, vanilla, orange,lemon, citrus, lime, grape, cherry, strawberry, chocolate, and coffee,including combinations thereof.

In another embodiment, one or more surfactants can be comprised withinthe bulk powder or within the binding liquid. The presence and identityof a surfactant can be independently selected upon each occurrence. Thebinding liquid or bulk powder can comprise one or more surfactants in arange from at least 0.1% by weight, and up to 4% by weight; or at least1% by weight, and up to 3% by weight; or at least 1.5% by weight, and upto 2.5% by weight.

In an embodiment, the one or more surfactants can be selected from thegroup consisting of polysorbate (PEG-ylated sorbitan (a derivative ofsorbitol) esterified with fatty acid) and a poloxamer, includingcombinations thereof. A polysorbate can be selected from the groupconsisting of: polysorbate 20 (Polyoxyethylene (20) sorbitanmonolaurate), polysorbate 40 (Polyoxyethylene (20) sorbitanmonopalmitate), polysorbate 60 (Polyoxyethylene (20) sorbitanmonostearate), polysorbate 80 (Polyoxyethylene (20) sorbitanmonooleate), sodium lauryl sulfate, poloxamer (comprising a central(poly(propylene oxide)) flanked by two chains of (poly(ethylene oxide),e.g. LUTROL®), and low molecular weight polyethylene glycol (e.g. PEG400), including combinations thereof. A poloxamer may be selected fromthe group consisting of poloxamers 124, 188, 237, 338, or 407, includingcombinations thereof.

In another embodiment, one or more preservatives can optionally becomprised within the bulk powder or within the binding liquid. Thepresence and identity of a preservative can be independently selectedupon each occurrence. Non-limiting examples of suitable preservativesinclude antifungal or antimicrobial preservatives such as methylparabenand propylparaben. In another embodiment, the binding liquid cancomprise at least 0.001% by weight, and up to 0.2% by weight, of one ormore preservatives.

In another embodiment, one or more glidants can optionally be comprisedwithin the bulk powder. The presence and identity of a glidant can beindependently selected upon each occurrence. The bulk powder cancomprise a glidant in a range from at least 0.1% by weight, and up to2.0% by weight; or at least 0.25% by weight, and up to 1.5% by weight;or at least 0.5% by weight, and up to 1.0% by weight of the bulk powder.The glidant can comprise fumed silica (colloidal silicon dioxide).

In another embodiment, two or more excipients can be comprised withinthe bulk powder material as a co-granulate, a non-limiting example ofwhich is Ludipress® (BASF Pharma), which comprises 93% (w/w) lactose,3.5% (w/w) povidone, and 3.5% (w/w) crospovidone.

In a non-limiting example, the bulk powder material can consist ofdextrose. In another non-limiting example, the bulk powder material canconsist of up to 75% (w/w) ascorbic acid, with the balance dextrose.

In various embodiments, the bulk powder material and/or the bindingliquid can comprise a medicament compound, including, for example, anyone or more of the medicaments listed below. A medicament includedwithin the bulk powder material and/or the binding liquid can be eitheridentical to or different from any medicament that is comprised within apayload deposited into the cavity of any of the rapidly-orodispersibletablets described herein. In a non-limiting example, a bulk powdermaterial can comprise metformin hydrochloride, microcrystallinecellulose, povidone, silica, corn starch, and optionally one or moresweeteners, particularly a sweetener selected from the group consistingof sucralose and monoammonium glycyrrhizinate, including combinationsthereof.

In another embodiment, the bulk powder and/or the binding liquid cancomprise glycerin (glycerol), which can exhibit characteristics of ahumectant, sweetener, preservative, lubricant, saponifier, or a solvent.The use of glycerin in 3DP dosage forms is described in U.S. Pat. Nos.9,314,429, 9,339,489, 9,492,380, 9,669,009, and 10,028,909, thedisclosures of which are incorporated by reference in their entireties.

In another embodiment, glycerin can be comprised within the bindingliquid. In another embodiment, the binding liquid comprises glycerin,water, and at least one organic solvent. In another embodiment, thebinding liquid can comprise glycerin in a range from at least 1% byweight, and up to 10% by weight; or at least 2% by weight, and up to 8%by weight; or at least 3% by weight, and up to 5% by weight of thebinding liquid. In another embodiment, the dosage form can compriseglycerin in a range from at least 0.05% by weight, and up to 5% byweight; or at least 0.25% by weight, and up to 2.0% by weight; or atleast 0.5% by weight, and up to 1.5% by weight; or at least 0.5% byweight, and up to 1.0% by weight, of the dosage form.

In another embodiment, the binding liquid can comprise one or moreorganic solvents in a range from at least 1% by weight, and up to 25% byweight; or at least 5% by weight, and up to 20% by weight; or at least10% by weight, and up to 15% by weight of the binding liquid. The one ormore organic solvents is an alcohol selected from the group consistingof ethanol, methanol, propanol, and isopropanol, including combinationsthereof.

To facilitate forming an interior cavity, the print head and nozzles ofthe 3D printing assembly can be configured or programmed to applydroplets of binding liquid upon any specific portion of a substantiallyuniform layer of powder, particularly a peripheral portion of the layer.FIGS. 5 and 6 show a non-limiting example of the deposition ofadditional predetermined amounts of powder that are deposited as orformed into intermediate incremental layers, with each layer having itsown substantially uniform thickness. In FIG. 5 , in the left side of theillustration, the binding liquid is applied only at the peripheralportions 25 b of a second substantially-uniform layer of powder material25 a, to form a second incremental layer 25 having a peripheral portionof wetted powder 25 c and leaving a central portion of unwetted, unboundpowder 25 d shown in the right side of the illustration. Subsequently, athird powder layer can be applied into a substantially-uniform thirdpowder layer upon the second incremental layer, and droplets of bindingliquid applied only at the peripheral portions of the powder material,to form a third incremental layer 26 having a peripherally-bound portion26 c and a central portion of unwetted, unbound powder 26 d as shown inFIG. 6 . Repeating the process to form fourth, fifth, sixth, and seventhincremental layers (27, 28, 29, and 30, respectively) results in acontainer 31 for a dosage form having a base 32, a peripheral wall 33,and a central cavity filled 34 with unwetted, unbound build powdermaterial 50, as shown in FIG. 6 .

Those skilled in the art would appreciate that a container formed by aprocess as described above can comprise any number of consecutiveintermediate-peripherally-bound layers to form the peripheral wall, andsuch examples are omitted for clarity. Additionally, the dosage form cancomprise any number of base powder layers, in which the entire layercomprises a bound powder matrix, prior to forming the peripherally-boundlayers that form the boundary of the internal cavity, and that suchexamples are also omitted for clarity. The completed dosage form canalso comprise any number of powder layers comprising an upper portion orlid of the dosage, in which the entire layer comprises a bound powdermatrix. In one non-limiting example, “end” portions of the dosage form,comprising either the base and/or upper portions of the dosage form, cancomprise 1 to 10, 1 to 7, 2 to 7, 2 to 5, or 4 to 6 printed incrementallayers. In another non-limiting example, intermediate portions of thedosage form that comprise the peripheral wall of the dosage form cancomprise 2 to 10, 2 to 7, 2 to 5, or 4 to 7 printed incremental layers.In a further embodiment, a portion of one or both of the “end” portions,or the peripheral wall, can have an indicium, source, or design printedinto the surface of the incremental layer(s).

In another embodiment, the peripherally-bound portion of incrementallayers that define the container peripheral wall can have asubstantially-uniform thickness. FIG. 7 shows an exemplary top view ofthe second incremental layer 25 of container 31, in a first quadrant (I)of the illustration, in which the peripheral wall 33 has a substantiallyuniform width, w1, encircling the central filled cavity 34. Forcylindrical containers, including rapidly-orodispersible containers,each of the incremental layers that define the peripheral wall 33 canhave the same substantially-uniform width, w. In another embodiment, thesubstantially-uniform width can be modified to affect such factorsincluding, but not limited to: the desired hardness and friability ofthe dosage form, the desired or required volume of the interior cavity,and/or the desired orodispersibility of the dosage form in a smallvolume of water. In another embodiment, the peripherally-bound portioncan have a substantially uniform width in a range from at least 0.5 mm,and up to 10 mm; or from at least 1.0 mm, and up to 5.0 mm; or from atleast 1.5 mm, and up to 3 mm. In another embodiment, the ratio of thesubstantially-uniform width, w, of the peripherally-bound portion,relative to the radius, r, of the entire layer can be at least 1:10, orat least 1:9, or at least 1:8, or at least 1:7, or at least 1:6, or atleast 1:5, and up to 1:4, up to 1:6 or up to 1:8. Non-limiting examplesof several peripherally-bound incremental layers having differentsubstantially-uniform width or thicknesses, relative to the radius ofthe container, are illustrated as wall width w2 in the second quadrant(II), as wall width w3 in the third quadrant (III), and as wall width w4in the fourth quadrant (IV) of the illustration of FIG. 7 , wherein aratio of the width or thickness w of the peripheral wall to the radiusor effective radius r of the container is from about 4:1 to about 1:8,and in some embodiments, from about 1:3 to about 1:6, or about 1:4 toabout 1:5.

In various embodiments, and illustrated with respect to a dosage formsimilar in shape to that of dosage form 1 of FIG. 1 , two non-limitingarrangements of two or more cavities within a container body areillustrated in FIGS. 8 and 9 . FIG. 8 depicts an arrangement of cavities91 a and 91 b within a container 90, wherein each cavity is bounded by aperipheral wall 92 and a bisecting interior wall 93. FIG. 9 depicts anarrangement of cavities 96 a, 96 b, and 96 c within a container 95, inwhich each cavity is bounded by a peripheral wall 97 and two interiorwalls 98 a and 98 b, 98 a and 98 c, or 98 b and 98 c, respectively. Inembodiments of the invention, the printing liquid can be applied ontothe powder layer within the printing area in a peripheral pattern thatforms the peripheral wall of the container body, and in one or morecontinuous lines extending into the interior area from the peripheralpattern that form the interior walls of the container body, to dividethe interior area of the dosage form into the two or more cavities thatare arranged and separated angularly (in pie-shaped segments areillustrated in FIGS. 8 and 9 , radially (in concentric rings), oraxially (in layers through the depth of the dosage form). Those skilledin the art would appreciate that there are countless print patterns thatcould be utilized to deposit a printing liquid in the center portion ofthe print area, in order to form any number of cavities defined byinterior walls.

Accordingly, a rapidly-orodispersible container can generally formed bya method comprising the following steps: forming arapidly-orodispersible container base and forming arapidly-orodispersible peripheral wall. In another embodiment, themethod for forming the container base can comprise the steps of: a)dispersing a powder material into a base powder layer; b) dispensing aprinting liquid comprising a binder material onto the base powder layerto form a bound base-matrix layer; and c) optionally repeating steps a)and b) one or more times, and the method for forming the peripheral wallcan comprise the steps of: d) dispersing the powder material into anintermediate powder layer atop the container base; e) dispensing theprinting liquid onto a peripheral portion of the intermediate powderlayer, without dispersing the printing liquid onto an interior portionof the intermediate powder layer, to form: a filled container consistingof a bound wall-matrix layer that is bound to the container base, and aninterior portion consisting of unbound powder material; and f)optionally repeating steps d) and e) one or more times.

In another embodiment, unbound powder material can be emptied from thefilled cavity using a powder evacuation apparatus and system. In someembodiments, the powder evacuation system can comprise a vacuum systemconfigured to fluidize and remove the powder material without damagingor disturbing the bound matrices that comprise the container base andperipheral wall. In a first non-limiting example, a vacuum system caninclude a vacuuming apparatus for removing unbound powder from a singlecavity is shown in FIG. 10 . The vacuuming apparatus 35 can be inposition to fluidize and remove unbound build powder material 50 fromthe cavity 34 of a rapidly-orodispersible container 31 within depression10. The vacuuming apparatus 35 comprises a suction cylindrical body 36having an outlet, suction end 37, and an inlet, powder end 38. Thevacuuming apparatus 35 is positioned within the depression 10 and insubstantially axial registry with the cavity 34 of therapidly-orodispersible container 31. A suction is applied to theinterior of the cylindrical body 36 by a remote vacuum source, asindicated by the arrow with the letter, “V”. The vacuum source can beregulated by any known device in the art that can provide a controllableamount of vacuum. The vacuum in the cylindrical body 36 results in anintake of air through the inlet end 38, causing particles of the buildpowder material 50 to be drawn out from the cavity 34 and into the inletend 38 of the vacuuming apparatus 36. The cylindrical body 36 and inletend 38 can be configured to be inserted into the partially-filled cavity34, as shown in FIG. 10 , to ensure complete removal of the unboundbuild powder material 50. As the inlet end 38 is lowered toward thecontainer base 32, the application of vacuum can be carefully controlledand decreased to reduce the risk that the incoming air flow will damageor disturb the matrix of powder and binder of the container base 32 andperipheral walls 33. Eventually, the entire volume of the unbound buildpowder material 50 is drawn from the cavity and out of the outlet end 37of the cylindrical body 36. In another embodiment, the unbound powderdrawn up by the vacuuming system can be deposited into a powderreservoir and stored for future use.

In an alternative embodiment of a powder evacuation apparatus andsystem, a smaller-diameter vacuum pipette, relative to the diameter orwidth of the cavity, can be used to vacuum the unbound powder materialfrom within the cavity of the built container body. As shown in FIG. 11, an inlet tip of a smaller-diameter vacuum pipette, can be placed abovethe surface of the unbound powder material. With a vacuum applied to theoutlet end of the pipette, the inlet tip can be lowered (in the verticalor y direction) into the unbound powder and maneuvered circumferentially(c direction) and radially or laterally (x,y direction) within thecavity to draw powder into the inlet tip and evacuate the unbound powderfrom the cavity.

In another embodiment, a powder evacuation apparatus can comprise aplurality of the vacuum pipettes, arranged in a matrix and configured oradapted to be moved in unison as a group, or individually, into andwithin a corresponding matrix of spaced-apart container bodies toevacuate their respective unbound powder.

In another embodiment of a powder evacuation apparatus and system,unbound powder material can be fluidized and removed from the cavitiesof a plurality of rapidly-orodispersible containers within the samebuild platform, particularly a plurality of containers within the samepackaging, such as a blister pack. The unbound powder can be fluidizedby directing a turbulent, i.e., multi-directional, air or gas glowimmediately above the filled cavity. In a further embodiment, ashielding or masking plate can be placed over the plurality ofcontainers, the plate having perforations that expose the unbound powderwithin the filled cavities, but also sequester the containersthemselves, as the turbulent air or gas flow is passed over thecavities.

In a non-limiting example and as illustrated in FIG. 12 , a vacuumingsystem can comprise a ventilated hood 40 disposed above a plurality ofrapidly-orodispersible containers 31 filled with unbound build powder 50and disposed within a plurality of depressions 10. In some embodiments,the plurality of depressions 10 can be disposed within a blister pack,or a plurality of blister packs. Within the ventilated hood 40, ambientair or gas can be drawn in through a plurality of air inlets 41 tocreate a turbulent air flow 43 above the containers, fluidizing andemptying the unbound build powder material 50 from each of the cavities34. The turbulent air and fluidized powder can both be evacuated fromthe hood by a suction applied to the interior of the body by a remotevacuum source at an outlet portion 42 of the hood 40. In anotherembodiment, the outlet portion can contain a screen, mesh, or filter forcollecting and/or redirecting the unbound powder material into a powderreservoir for future use, as described above, while allowing the air orgas to pass through the outlet freely.

FIG. 12 illustrates the effect of the turbulent air flow 43 above one ofthe cavities 34, illustrated in four illustrated segments. The firstsegment A illustrates a container 31 within a depression 10, and withunbound build powder material 50 within the cavity 34. The secondsegment B illustrates a turbulent air flow 43 being created above thepowder-filled container 31 within the depression 10. The second segmentC illustrates the unbound build powder material 50 being fluidized,drawn upward, and evacuated from the cavity 34, leaving therapidly-orodispersible container 31 with an emptied cavity 34 within thedepression 10 as shown in fourth segment D.

In another embodiment a powder evacuation apparatus and system, insteadof using a vacuuming system to remove the unbound powder material from acavity, a rapidly-orodispersible container can instead be manually ormechanically inverted, and the powder material decanted from thecontainer.

In another embodiment, a rapidly-orodispersible container can besubjected to high-frequency shaking or external sonication, whereby theunbound powder is substantially ejected from the cavity. Shaking orsonication may be applied when the container body is upright orinverted, and with a controlled frequency that empties the powdermaterial from the cavity, without disturbing or damaging thebound-powder matrix of the container. Systems for shaking and/orsonicating objects are well known in the art.

In various embodiments, the powder evacuation apparatuses describedherein are controlled by an automated controller system to evacuateunbound powder from built container bodies within the container-formingsystem.

In various embodiments, once unbound powder material is removed from arapidly-orodispersible container, the emptied cavity can then be filled,either partially or fully, with one or more solid, powdered, orparticulate medicaments. In another embodiment, each of the one or moremedicaments can be a fine, coarse, or granulated powder. In anotherembodiment, each of the one or more medicaments can be water-soluble, orcan be aqueous fluid-soluble, partially water-soluble, partially aqueousfluid-soluble, water-insoluble, or aqueous fluid-insoluble.

In another embodiment, one or more of the medicaments can be coated,taste-masked, agglomerated, and/or cross-linked. Components fortaste-masking a medicament are described in U.S. Pat. No. 9,492,380, thedisclosure of which is incorporated by reference in its entirety.Methods for taste-masking can include the addition of a coating,non-limiting examples of which include water-insoluble coatings,acid-soluble coatings, cationic polyacrylate coatings, polymethacrylatecoatings, ion exchange resins coated with an ingestible polymer, ethylcellulose coatings, and cellulose polymers. A medicament can betaste-masked using a waxy material, which is not an ionic polymer orcopolymer, an acrylate polymer or copolymer, a methacrylate polymer orcopolymer, or an enteric polymer. The waxy material can be selected fromthe group consisting of glyceryl dipalmitostearate (BIOGAPRESS VEGETAL),glyceryl distearate (PRECIROL®), glycerol palmitostearate, glyceryldibehenate (COMPRITOL 888), mono and diglyceride mixture (GELEOL),glycerol monostearate, beeswax, carnauba wax, or cetyl esters wax. Thewaxy material can be glyceryl dipalmitostearate or glyceryl distearate.Processes and systems for forming pre-agglomerated powder particles aredescribed in U.S. Pat. No. 9,314,429, the disclosure of which isincorporated by reference in its entirety.

In another embodiment, two or more medicaments can be combined into apowder composition and deposited into a single cavity. In anotherembodiment, a first medicament can be deposited into a first cavity, asecond medicament can be deposited into a second cavity, and so on, suchthat a container having a plurality of cavities can contain a singlemedicament in each cavity, typically segregated and out of physicalcontact with the other. In another embodiment, the one or moremedicaments can be combined with one or more solidpharmaceutically-acceptable excipients to form a composition. In anotherembodiment, the one or more solid pharmaceutically-acceptable excipientscan be selected from any of the excipients described above. In anotherembodiment, the one or more solid pharmaceutically-acceptable excipientscan comprise an unbound form of the powder material used to form thebound-powder matrix. In a further embodiment, the one or more solidpharmaceutically-acceptable excipients can consist only of the powdermaterial.

In another embodiment, the solid medicament deposited into a cavity canbe any powdered, particulate, crystalline, or agglomerated medicament.In another embodiment, the medicament can be selected from any of themedicaments approved for treatment by the Food and Drug Administration(FDA) (see e.g., “Approved Drug Products with Therapeutic EquivalenceEvaluations”, 40th Edition, U.S. Department of Health and Human Services(2020)). Non-limiting examples of pharmacological activities and/ormedicaments include: local anesthetics, antiepileptic drugs andanticonvulsants; anti-Alzheimer's disease drugs; analgesics;antipodagrics; anti-hypertensive drugs; antiarrhythmic drugs: diureticdrugs; drugs for treating liver diseases; drugs for treating pancreaticdiseases; antihistamines; anti-allergics; glucocorticoids; sex hormonedrugs and contraceptives; hypoglycemic drugs; anti-osteoporosis drugs;antibiotics; sulfonamides; quinolones; and other synthetic antibacterialdrugs; anti-tuberculous drugs; antiviral drugs; anti-neoplasm drugs;immune-modulators, cosmetically active agents; and anti-cancer drugs. Inanother embodiment, the medicament can be selected from the groupconsisting of: (R)-folitixorin, lidocaine, 11-di-deutero-ethyllinoleate,16-dehydro-pregnenolone, 17-beta-estradiol, 2-iminobiotin,3,5-diiodothyropropionicacid, 5-fluoro-2-deoxycytidine,6-mercaptopurine, edotreotide, abacavir, abalone haemocyanin,abametapir, abediterol, abemaciclib, abexinostat, abiraterone,acalabrutinib, acamprosate, acamprosatecalcium, acarbose, acebilustat,aceclidine, aceclofenac, acehytisine hydrochloride, acemannan,aceneuramic acid, acetaminophen, acetylcysteine, acetylkitasamycin,acetyl-L-carnitinehydrochloride, acetylsalicylicacid, aciclovir,acipimox, acitazanolast, acitretin, aclidinium, aclidinium bromide,acolbifene, acorafloxacin, acotiamide, acrivastine, actarit, adapalene,adapalene, adefovirdipivoxil, ademetionine, adoair, afatinib,afimoxifene, afuresertib, agomelatine, ail denafilcitrate, aladorian,alalevonadifloxacin mesylate, alarelin acetate, alatrofloxacin mesylate,albendazole, albuterol sulfate, albuterpenoids, alcaftadine,aldoxorubicin, alectinib, alendronate, alendronate sodium, alendronatesodiumhydrate, alendronic acid, alfacalcidol, alfaxalone, alfentanil,alfuzosin, alisertib, aliskiren, alisporivir, alitretinoin, allantoin,alli sartani soproxil, allopurinol, almotriptan, alogliptin, alogliptinbenzoate, alosetron, alpelisib, alphaketoglutarate, alphalipoic acid,alpha-lantitrypsin, alpha-cyclodextrin-stabilized sulforaphane,alprazolam, alprostadil, alprostadil alfadex, altiratinib, altretamine,altropane, aluminum sulfate, alvimopan, alvocidib, amantadine,amantadine hydrochloride, ambrisentan, ambroxol, ambroxol hydrochloride,amcasertib, amfetamine, amfetamine polistirex, amifampridine,amifampridine phosphate, amifostine, amikacin, amiloride,aminolevulinic, aminolevulinic acid, aminolevulinic acid hydrochloride,aminopterin, amiodarone, amiselimod, amisulpride, amitifadinehydrochloride, amitriptyline, amlexanox, amlodipine, amlodipine,amlodipinebesilate, amlodipine besylate, amlodipine camsylate,amlodipine maleate, amlodipine nicotinate, amlodipine orotate, ammoniumlactate, amodiaquine, amorolfine, amosulalol, amoxicillin, amoxicillinhydrate, amphetamine, amphetamine aspartate, amphetamine sulfate,amphotericinB, amphotericinB cholesterylsulfate, amphotericinB lipidcomplex, ampicillin sodium, ampiroxicam, amrinone, amrubicin,amtolmetinguacil, anacetrapib, anagliptin, anagrelide, anamorelin,anastrozole, ancrod, androgen, andrographolide, anecortave,anidulafungin, aniracetam, anistreplase, anlotinib, antazoline,antiandrogens, antineoplaston A-10, antineoplaston AS2-1, antofloxacinhydrochloride, antroquinonol, apabetalone, apalutamide, apatinibmesylate, apaziquone, apilimod mesylate, apixaban, apomorphine,apomorphine hydrochloride, apremilast, aprepitant, apricitabine,aramchol, aranidipine, arasertaconazole, arasertaconazol enitrate,arbaclofen, arbaclofen placarbil, arbekacin, arbekacin sulfate,ardeparin sodium, arformoterol, argatroban, arhalofenate, arimoclomol,aripiprazole, aripiprazole lauroxil, arsenictrioxide, arsenious acid,artefenomelmesylate, artemether, artemotil, artenimol, arterolanemaleate, artesunate, Artiss, asapiprant, asenapine, asimadoline,astodrimer, astragaloside, asunaprevir, ataciguat, ataluren, atazanavir,atazanavir sulfate, atenolol, atomoxetine, atorvastatin, atorvastatincalcium, atorvastatin strontium, atovaquone, atrasentan, atropine,auranofin, auriclosene, avacincaptadpegol sodium, avacopan, avanafil,avatrombopag, avibactam, avibactam sodium, AvidinOx, aviptadil,avitinib, avoral stat, axelopran, axitinib, azacitidine, azacytidine,azasetron, azelaicacid, azelastine, azelastine hydrochloride,azeliragon, azelnidipine, azilsartan, azilsartan medoxomil potassium,azilsartan trimethylethanolamine, azimilide, azithromycin, azithromycinlactobionate, aztreonam, aztreonam lysine, azvudine, baclofen,bafetinib, Baicalein, baicalin, BAK-freelatanoprost, balofloxacin,balsalazide, balsalazide sodium, bambuterol, barasertib, bardoxolonemethyl, baricitinib, barnidipine, basmi sanil, batefenterol succinate,bazedoxifene, beclabuvir, beclometasone dipropionate, beclomethasonedipropionate, bedaquiline, bedoradrine, belinostat, beloranib,belotecan, bempedoic acid, benapenem, benazepril, bencycloquidiumbromide, bendamustine, bendamustine hydrochloride, benidipine,benserazide, bentamapimod, benzalkonium chloride, benzhydrocodone,benznidazole, benzocaine, benzoylperoxide, benzydamineHCL, bepotastine,bepotastine calciumdihydrate, bepotastine salicylate, beractant,beraprost sodium, besifloxacin, besifovir, besipirdine, beta-elemene,betahistine, betaine anhydrous, betamethasone, betamethasone butyratepropionate, betamethasonedipropionate, betamethasone valerate,betamipron, betaxolol, betaxolol hydrochloride, bethanechol, betrixaban,bevacizumab, bexagliflozin, bexarotene, bezafibrate, biafungin,biapenem, bicalutamide, bicizar, bictegravir, bicyclol, bilastine,bimatoprost, binimetinib, biotin, birabresibdihydrate, biskalcitratepotassium, bismuth subgallate, bismuthyl ecabet, bisnorcymserine,bisoprolol, bisoprolol fumarate, bitespiramycin, bixalomer, bleomycin,blonanserin, boanmycin hydrochloride, boceprevir, bortezomib, bosentan,bosentan hydrate, bosutinib, bovactant, brexpiprazole, briciclib sodium,brigatinib, brilacidin, brimapitide, brimonidine, brincidofovir,brinzolamide, brivanibalaninate, brivaracetam, brivudine, brolucizumab,bromazepam, bromfenac, bromfenac sodium, bromocriptine, bronchostat,brotizolam, bryostatin-1, bucindolol, bucladesine, budesonide, budipine,buflomedil, bulaquin, bunazosin, buparlisib, bupivacaine, bupivacainehydrochloride, buprenorphine, buprenorphine hydrochloride, bupropion,bupropion hydrochloride, burixafor, buserelin acetate, buspirone,buspirone hydrochloride, busulfan, busulfex, butenafine, butorphanoltartrate, butylphthalide, cabazitaxel, cabergoline, cabotegravir,cabozantinib S-malate, cadazolid, cadrofloxacin, caffeine, caffeinecitrate, cafnea, cafusertib hydrochloride, calcipotriol, calcitriol,calcium acetate, calciumfolinate, calcium levofolinate, calciumpolycarbophil, calfactant, calmangafodipir, calsurf, camicinal, camostatmesylate, camptothecin, canagliflozin, candesartan, candesartancilexetil, canfosfamide, cangrelor, cannabidiol, capecitabine,capmatinib, capsaicin, captopril, carbamazepine, carbetocin, carbidopa,carbinoxamine, carbocysteine, carboplatin, cardidopa, carfilzomib,carglumicacid, cariprazine, carisbamate, carmustine, carotegastmethyl,carteolol, carteolol hydrochloride, carumonam, carvedilol,carvedilolphosphate, caspofungin, catechin, cebranopadol, cediranib,cefaclor, cefadroxil, cefathiamidine, cefazolin sodium pentahydrate,cefcapene, cefdinir, cefditorenpivoxil, cefepime, cefepimedihydrochloride, cefetametpivoxil hydrochloride, cefiderocol,cefilavancin, cefminox, cefoperazone, cefoperazone sodium, cefoselis,cefotaxime, cefotaxime sodium, cefotiam, cefozopran, cefpirome,cefpodoxime, cefprozil, ceftaroline, ceftaroline fosamil, ceftazidime,ceftibuten, ceftobiprole medocaril, ceftolozane sulfate, ceftriaxone,ceftriaxone sodium, cefuroxime, cefuroxime sodium, celecoxib,celgosivir, celiprolol, cellprotect, cenestin, cenicriviroc,censavudine, centanafadine, cephalosporin, ceralifimod, cerdulatinib,ceritinib, ceriumnitrate, cetilistat, cetirizine, cetraxate, cevimeline,chenodeoxycholic acid, chlocibutamine, chlorhexidine, chlormadinoneacetate, chlorogenicacid, chloroquine, chloroxoquinoline,chlorpheniramine, chlorpheniramine maleate, chlorpheniramine polistirex,chlortalidone, chlorthalidone, cholecalciferol, cholic acid, cholinealfoscerate, choline diepalrestat, choline fenofibrate, ciclesonide,ciclopiroxolamine, ciclosporin, cidofovir, cidoxepin, cilastatin,cilazapril, cilnidipine, cilostazol, cimetidine, cinacalcet, cinepazidemaleate, cinhyaluronate sodium, cinitapride tartrate, cipargamin,ciprofibrate, ciprofloxacin, ciprofloxacin hydrochloride, ciraparantag,circadin, cisatracurium besilate, cisplatin, citalopram, citalopramhydrobromide, citicoline, citrulline, cladribine, clarithromycin,clavulanate potassium, clavulanic acid, clazosentan, clevidipine,clevudine, clindamycin, clindamycin hydrochloride, clindamycinphosphate, clioquinol, clobazam, clobetasolpropionate,clobetasolpropionatefoam, clodronic acid, clofarabine, clofazimine,clomipramine, clomipramine hydrochloride, clonazepam, clonidine,clonidine hydrochloride, clopidogrel, clopidogrel besylate, clopidogrelbi sulfate, clopidogrel camsylate, clopidogrel hydrogensulfate,clopidogrel napadisilate, clopidogrel resinate, clotrimazole, clozapine,cobamamide, cobicistat, cobimetinib, cobiprostone, codeine, codeinepolistirex, colchicine, colecalciferol, colesevelam, colestilan,colforsin daropate, colfosceril palmitate, colistimethate sodium,conivaptan, copanlisib, copperhistidine, cortexolone 17alpha-propionate,cositecan, crenolanib, cridanimod sodium, crisaborole, crizotinib,crofelemer, crolibulin, cromoglicic acid, cromolyn sodium, cutamesinedihydrochloride, cyanocobalamin, cyclizine lactate, cyclobenzaprinehydrochloride, cyclophosphamide, cyclophosphamide monohydrate,cyclosporin, cyproterone, cyproterone acetate, cytarabine, cytarabineocfosfate, dabigatran etexilate, dabrafenib, daclatasvir, dacomitinib,dalbavancin, dalcetrapib, dalfampridine, dalfopristin, dalteparinsodium, danaparoid sodium, danazol, danirixin, danoprevir, dantrolenesodium, danusertib, dapaconazole, dapagliflozin, dapagliflozinpropanediol, dapiprazole, dapivirine, dapoxetine, daprodustat, dapsone,darifenacin, darinaparsin, darunavir, dasabuvir, dasatinib, dasotraline,daunorubicin, decitabine, decuprate, defactinib, deferasirox,deferiprone, deferoxamine mesylate, deflazacort, deflexifol,delafloxacin, delamanid, delapril, delapril hydrochloride, delavirdine,denibulin, deoxyandrographolide, dematansulfate, desflurane, desipraminehydrochloride, desloratadine, desmopressin, desmopressin acetate,desogestrel, desonide, desvenlafaxine, deudextromethorphan hydrobromide,deuteporfin, deuterated levodopa, deuteratedvenlafaxine,deutetrabenazine, dexamethasone, dexamethasone acetate, dexamethasonecipecilate, dexamethasone palmitate, dexamethasone sodiumphosphate,dexamfetamine, dexanabinol dexferrum, dexketoprofen trometamol,dexlansoprazole, dexmedetomidine, dexmethylphenidate, dexpramipexole,dexrazoxane, dexsotalol, dextroamphetamine saccharate, dextroamphetaminesulfate, dextromethorphan, dextromethorphan hydrobromide,dextropropoxyphene, diacerein, diamorphine hydrochloride,dianhydrogalactitol, diazepam, diazoxidecholine, diclofenac, diclofenacpotassium, diclofenac sodium, diclofenamide, dicycloplatin, didanosine,dienogest, difluprednate, digoxin, dihomogamma-linolenic acid,dihydroergocristine, dihydroergotamine, dihydroergotamine mesylate,diltiazem, diltiazem hydrochloride, dimesna, di methyl fumarate,dimiracetam, dinoprostone, diphenylcyclopropenone, dipraglurant,dipyridamole, diquafosoltetra sodium, dirithromycin, disufentonsodium,disulfiram, dithranol, d-methadone, docarpamine, docetaxel, dociparstat,docosanol, dofetilide, dolasetron, dolutegravir, domperidone, donafenibtosylate, donepezil, donepezil hydrochloride, dopamine, doravirine,doripenem, dorzolamide, dorzolamide hydrochloride, dosmalfate,doxacurium chloride, doxazosin, doxazosin mesylate, doxepinhydrochloride, doxercalciferol, doxifluridine, doxofylline, doxorubicin,doxorubicin hydrochloride, doxycycline, doxycycline hyclate, doxylaminesuccinate, dronabinol, dronedarone, drospirenone, droxidopa, D-tagatose,duloxetine, duloxetine hydrochloride, dutasteride, duvelisib, ebastine,eberconazole, ebselen, ecabet, econazolenitrate, ecopipam, edaravone,edivoxetine, edonerpic maleate, edoxaban, efatutazone, efavirenz,efinaconazole, eflornithine, efonidipin hydrochloride, egualen sodium,eicosapentaenoic acid monoglycerides, elafibranor, elagolixelamipretide, elbasvir, eldecalcitol, eleclazine, elesclomol sodium,eletriptan, eliglustattartrate, elobixibat, eltrombopag, eluxadolinedihydrochloride, elvitegravir, emdogain, emedastine, emeramide,emixustat, emodepside, empagliflozin, emricasan, emtricitabine,enalapril, enalaprilmaleate, enasidenib, encenicline, enclomifenecitrate, encorafenib, endoxifen, enobosarm, enoxacin gluconate,enoxaparin sodium, enprostil, entacapone, entasobulin, entecavir,entecavir maleate, entinostat, entospletinib, entrectinib, enzalutamide,enzastaurin, epacadostat, epalrestat, eperisone, epetraborole, ephedrinesulfate, epinastine hydrochloride, epinephrine, epirubicin, epirubicinhydrochloride, episalvan, epitinib, eplerenone, epoprostenol,epristeride, eprodisate, eprosartan, eptaplatin, eravacycline,erdafitinib, erdosteine, eribulin mesylate, erlotinib, ertapenem,erteberel, ertugliflozin, erythromycin, erythromycin acistrate,erythromycin stinoprate, escitalopram, esketamine, esketaminehydrochloride, eslicarbazepine acetate, esmolol hydrochloride,esomeprazole, esomeprazole magnesium, esomeprazole strontium,esomeprazole, estetrol, estradiol, estradiol acetate, estradiolcypionate, estradiol valerate, estrodiol, estrogen, esuberaprost sodium,eszopiclone, etamicastat, ethambutol hydrochloride, ethaselen,ethinylestradiol, ethylhydrogenfumarate calcium, ethylhydrogenfumaratemagnesium, ethylhydrogenfumara tezinc, ethynylestradiol, etidronicacid,etimicin sulfate, etirinotecanpegol, etizolam, etodolac, etonogestrel,etoposide, etoposide phosphate, etoricoxib, etravirine, etripamil,eupatilin, evenamide hydrochloride, everolimus, evofosfamide,evogliptin, exemestane, exendin(9-39), exeporfinium chloride,ezatiostat, ezetimibe, ezutromid, fadolmidine, fadrozole, faldaprevir,falecalcitriol, famciclovir, famitinib, famotidine, fampridine,faropenem, fasitibant chloride, fasoracetam, fasudil, fasudilhydrochloride, fasudil mesylate, favipiravir, febarbamate, febuxostat,fedovapagon, felbamate, felbinac trometamol, felodipine, femitra,fenfluramine hydrochloride, fenobam, fenofibrate, fenofibric acid,fenoldopam, fenoterol, fenretinide, fentanyl, fentanyl citrate,fenticonazole, fermagate, ferriccitrate, ferricmaltol, ferumoxytol,fesoterodine fumarate, fevipiprant, fexinidazole, fexofenadine,fibrinsealant, fibrinogen, fibrinogensealant, fidaxomicin, filanesib,filgotinib, filociclovir, fimaporfin, fimasartan, finafloxacin,finafloxacin hydrochloride, finasteride, finerenone, fingolimod,fipamezole, firtecanpegol, flecainide, fleroxacin, flibanserin,flomoxef, floxuridine, fluazolepali, fluconazole, fludarabine,flumatinib, flumazenil, flunisolide, fluocinolone acetonide,fluocinonide, fluorapacin, fluorouracil, fluoxetine, fluoxetinehydrochloride, flupirtine, flurbiprofen, flurbiprofenaxetil,flurbiprofen sodium, flurithromycin, fluticasone, fluticasone furoate,fluticasone propionate, flutrimazole, fluvastatin, fluvoxamine, folicacid, folinate, foliumginkgo, fomepizole, fonadelpar, fondaparinuxsodium, foretinib, formestane, formoterol, formoterol fumarate,forodesine, fosamprenavir, fosaprepitant, fosbretabulin, fosbretabulindisodium, fosfluconazole, fosfomycin, fosfomycindi sodium,fosfomycintrometamol, fosinopril, fosinopril sodium, fosmidomycin,fosphenytoin, fospropofol, fosravuconazole, fostamatinib, fostemsavirtromethamine, fotagliptin benzoate, fotemustine, frovatriptan,fruquintinib, fudosteine, fulvestrant, funapide, furosemide, fusidicacid, gabapentin, gabapentinenacarbil, gabexate mesylate, gacyclidine,gadobutrol, gadoversetamide, gadoxetate disodium, galantamine,galeterone, galidesivir, gallium nitrate, galunisertib, gambogic acid,ganaxolone, ganciclovir, ganetespib, ganirelix acetate, garenoxacin,gatifloxacin, gatifloxacin mesylate, gedatolisib, gefitinib, gemcabene,gemcitabine, gemcitabine hydrochloride, gemfibrozil, gemifloxacin,gemigliptin, gemigliptintartaric acid, genistein, gentamicin,gentiopicrin, gepirone, gepotidacin, gestodene, gestrinone, timololmaleate, gilteritinib, gimeracil, ginsenosideC-K, ginsenosideRg3,givinostat, glasdegib, glatiramer acetate, glecaprevir, glesatinibglycolate, glibenclamide, gliclazide, glimepiride, glipizide,glufosfamide, glutamine, glutathionarsenoxide, glycerol phenylbutyrate,glycopyrronium, glycopyrronium bromide, glycopyrronium tosylate,glycyrrhizi cacid, ganglioside, golotimod, gosogliptin, granisetron,granisetron hydrochloride, grazoprevir, guaifenesin, guaimesal,guanfacine, gusperimus trihydrochloride, haemophilusinfluenzae,halobetasol propionate, halofantrine, halometasone, healon,hematoporphyrin, hemearginate, hemocoagulase acutus, heparin, Herbiron,hetrombopag, hextend, higenaminehydrochloride, histamine dihydrochlorideHPPHphotosensitizer, humanapotransferrin, humanplasminogen, huperzineA,hyaluronate sodium, hydralazine, hydrochloride, hydrochlorothiazide,hydrocodone, hydrocodone bitartrate, hydrocodone polistirex,hydrocortisone, hydrogenperoxide, hydromorohone, hydromorphonehydrochloride, hydroxocobalamin, hydroxycarbamide, hydroxychloroquine,hydroxyprogesterone caproate, hydroxysafflor yellowA, hylastan,hypericin, hypoestoxide, ibandronate, ibandranic acid, iberogastN,ibodutant, ibrutinib, ibudilast, ibuprofen, ibutilide, ibutilidefumarate, icosabutate, icosapent, icosapentethyl, icosapentethyl ester,icotinibhydrochloride, idalopirdine, idasanutlin, idebenone, idelalisib, idoxuridine, idronoxil, ifetroban, ifetrobansodium, iguratimod,ilansoprazole, ilaprazole, iloperidone, iloprost,iloprostbetadexclathrate, imatinib, imatinibmesylate, imeglimin,imidafenacin, imidapril, imidazole salicylate, imidol hydrochloride,imigliptin dihydrochloride, imipenem, imiquimod, imisopasem manganese,imrecoxib, incadronic acid, incobotulinumtoxin, indacaterol, indacaterolmaleate, indapamide, indeloxazine, Indimitecan, indinavir, indisetron,indometacin, indoramin, indotecan, indoximod, inecalcitol, infigratinib,Ingavirin, ingenolmebutate, inhaled sodium nitrite, ferriccarboxymaltose, inosine, intepirdine, iodiconazole, ipatasertibdihydrochloride, ipragliflozin, ipratropium, ipratropium bromide,iptakalim, irbesartan, irinotecan, irinotecan hydrochloride, irinotecansucrosofate, irofulven, iron isomaltoside1000, iron protein succinylate,irosustat, irsogladine maleate, isavuconazonium chloride/sulfate,isodibut, isoflurane, isoniazid, isopropylunoprostone, isosorbidedinitrate, isosorbide mononitrate, isosteviol, isothiafludine,isotretinoin, isradipine, istaroxime, istradefylline, itacitinib,itopride hydrochloride, itraconazole, ivabradine hemisulfate, ivabradinehydrochloride, ivacaftor, ivermectin, ivosidenib, aflibercept,ixabepilone, ixazomib citrate, kallikrein, kangbeide, ketamine,ketanserin, ketoconazole, ketoprofen, ketorolac, ketorolac tromethamine,ketotifen, kevetrin, kukoamine Bmesylate, L-4-chlorokynurenine,lacidipine, lacosamide, lactitol, ladarixin, ladostigil, laflunimus,lafutidine, lamivudine, lamotrigine, landiolol, landiolol hydrochloride,laninamivir octanoate, lanoconazole, lansoprazole, lanthanum carbonate,lapatinib, laquinimod, laromustine, lasmiditan, lasofoxifene,latanoprost, latanoprostenebunod, lauflumide, ledipasvir, lefamulin,leflunomide, lemborexant, lenalidomide, lentinan, lentinansulfate,lentinanviral, lenvatinib mesylate, lercanidipine, lesinurad,leteprinim, letermovir, letrozole, leucine, leuprorelin acetate,levalbuterol, levalbuterol hydrochloride, levamisole, levamlodipine,levamlodipine besylate, levamlodipine maleate, levetiracetam,levobupivacaine, levocabastine, levocabastine hydrochloride,levocarnitine, levocetirizine dihydrochloride, levodopa, levodoxazosinmesylate, levofloxacin, levoketoconazole, levomilnacipran,levonadifloxacin arginine salt, levonorgestrel, levonorgestrelbutanoate, levo-phencynonate hydrochloride, levornidazole, levorphanol,levosimendan, levothyroxine sodium, levotuss, L-glutamine, lidocaine,lifitegrast, ligustrazine hydrochloride, limaprost, linagliptin,linezolid, liothyronine, liothyronine sodium, lipobean, liposomalcurcumin, lipoteichoic acid, liranaftate, lisdexamfetamine, lisinopril,lisofylline, lisuridehydrogen maleate, lithiumcitrate, lithiumsuccinate,lixivaptan, lobaplatin, lobeglitazone, lodenafil carbonate, lofexidine,lomefloxacin, lomerizine, lomerizine dihydrochloride, lomitapide,lonafarnib lonidamine, loperamide, loperamideoxide, lopinavir,loratadine, lorazepam, lorcaserin, lorediplon, lorlatinib,L-ornithineL-aspartate, lornoxicam, losartan, losartan potassium,losmapimod, loteprednoletabonate, lovastatin, loxapine, loxoprofen,L-praziquantel, lubiprostone, lucanthone, lucerastat, lucinactant,lucitanib hydrochloride, luliconazole, lumacaftor, lumateperone toluenesulfonate, lumefantrine, lumiracoxib, lunacalcipol, lurasidone,lurbinectedin, luseogliflozin hydrate, lusutrombopag, lysineacetylsalicylate, macimorelin, macitentan, mafenide, magnesiumcarbonate, magnesium isoglycyrrhizinate, mangafodipir, manidipine,manidipine dihydrochloride, mannitol, maraviroc, maribavir, marizomib,masilukast, masitinib, mavoglurant, maxacalcitol, mebendazole, mebiphon,mecamylamine, mecamylamine hydrochloride, mechlorethamine, mecobalamin,medroxyprogesterone, medroxyprogesteroneacetate, mefloquine, megestrol,megestrolacetate, meisuoshuli, melevodopa, meloxicam, melphalan,melphalanflufenamide hydrochloride, memantine, memantine hydrochloride,menadione sodium bisulfite, menatetrenone, mepacrine, mequinol,mercaptamine, mercaptamine bitartrate, mercaptamine hydrochloride,mercaptopurine, merestinib, meropenem, merotocin, mesalamine,mesalazine, metacavir, metadoxine, metamizolesodium, metaxalone,metergoline, metformin, metformin hydrochloride, methadone,methazolamide, methotrexate, methoxyflurane, methylaminolevulinatehydrochloride, methylnaltrexone bromide, methylnaltrexone,methylphenidate, methylphenidate hydrochloride, methylprednisolone,methylprednisolone aceponate, methylthioninium chloride, metirosine,metoclopramide, metoprolol, metoprolol succinate, metrifonate,metronidazole, metyrapone, mexiletine, mibefradil, miconazole,miconazole nitrate, midazolam, midazolam hydrochloride, midodrine,midostaurin, mifamurtide, mifepristone, migalastat, miglitol, miglustat,milnacipran, milrinone, miltefosine, minaprine, minocycline, minocyclinehydrochloride, minodronic acid, minoxidil, mirabegron, miriplatinhydrate, mirodenafil, mirodenafil hydrochloride, mirogabalin,mirtazapine, misoprostol, mitiglinide, mitomycin, mitoxantrone,mitoxantrone hydrochloride, mivotilate, mizolastine, mizoribine,mocetinostat dihydrobromide, moclobemide, modafinil, doxycycline,modipafant, moexipril, mofezolac, molidustat, molindone hydrochloride,momelotinib, mometasone, monepantel, monoammonium glycyrrhizinate,monobenzone, monosodium alphaluminol, monoterpene perillyl alcohol,montelukast, montelukast sodium, montmorillonite, moracizine,morinidazole, morphine, morphine glucuronide, morphine pitavastatin,morphine sulfate, morphothiadine mesilate, mosapride, motolimod,moxidectin, moxifloxacin, moxifloxacin hydochloride, moxonidine,moxonidine hydrochloride, mozavaptan, muparfostat sodium, mupirocin,mycobactovir, mycophenolatemofetil, myristylnicotinate, nabilone,nabiximols, nabumetone, N-acetylcysteine, nacystelyn, nadifloxacin,nadolol, nadroparin calcium, naftifine hydrochloride, naftopidil,nalbuphine, nalbuphine sebacate, naldemedine, nalfurafine, nalmefene,naloxegol, naloxone, naloxone hydrochloride, naltrexone, naltrexonehydrochloride, naluzotan, nandrolone decanoate, napabucasin,naphazoline, naphthoquine, naproxen, naproxen sodium, naquotinibmesylate, naratriptan, narlaprevir, nasapaque, nasaruplase,nastorazepide calcium, nateglinide, navamepent, nazartinib, nebivolol,necuparanib, nedaplatin, nedocromil, nelarabine, nelfinavir,nelotanserin, nemonapride, nemonoxacin, neoandrographolide,neosaxitoxin, neostigmine methyl sulfate, nepadutant, nepafenac,nepicastat, nepolong, neramexane, neratinib, neridronic acid,netarsudil, netilmicin, netupitant, nevirapine, niacin, nicardipine,nicergoline, nicorandil, nicotiflorin, nicotine, nicotinicacid,nicousamide, nifedipine, nifekalant, nifeviroc, Nifurtimox, nifurzide,nikkomycin, nilotinib, nilutamide, nilvadipine, nimesulide, nimodipine,nimorazole, ningetinib, nintedanib, niraparib, nisoldipine,nitazoxanide, nitisinone, nitrendipine, nitricoxide, nitroglycerin,nitroglycerine, nizatidine, nokxaban, nolatrexed, nomegestrol acetate,norelgestromin, norepinephrine, norethindrone, norethindrone acetate,norethindrone enantate, norethisterone, norethisterone acetate,norfloxacin, norgestimate, noribogaine, norursodeoxycholic acid,obeticholicacid, octenidine, octohydroaminoacridine succinate,octreotide, octreotide hydrochloride, odalasvir, odanacatib, odiparcil,ofloxacin, olanzapine, olaparib, olesoxime, oliceridine, olmesartan,olmesartan cilexetil, olmesartan medoxomil, olodaterol, olodaterolhydrochloride, olopatadine, olopatadine hydrochloride, olprinone,olsalazine, oltipraz, omacetaxine mepesuccinate, omadacycline,omarigliptin, omaveloxolone, ombitasvir, omecamtivmecarbil, omega-3carboxylicacids omeprazole, omigapil, omoconazole, onalespib,onapristone, ondansetron, ondelopran, opicapone, opipramol,methylphenidate, orcinoside, orilotimod, oritavancin, orlistat,ornithine phenyl acetate, ornoprostil, ortataxel, orteronel, orthovisc,orvepitant, oseltamivir, osilodrostat, osimertinib, Osiris Phleumpratense, ospemifene, oteracil potassium, oteseconazole, oxaliplatin,oxaloacetic acid, oxandrolone, oxazepam, oxcarbazepine, oxfendazole,oxidizedglutathione sodium, oxiracetam, oxybutynin, oxybutyninhydrochloride, oxycodone, oxycodone hydrochloride, oxymetazoline,oxymetazoline hydrochloride, oxymorphone, oxytocin, ozagrel, ozagrelhydrochloride, ozagrelsodium, ozanimod, ozenoxacin, paclitaxel,paclitaxel poliglumex, pacritinib, palbociclib, paliperidone,paliperidone palmitate, palmidrol, palonosetron, palovarotene,pamidronate disodium, pancrelipase, panipenem, panobinostat,pantoprazole, paracetamol, parecoxib, paricalcitol, paritaprevir,parnaparin sodium, parogrelil, paromomycin, paroxetine, paroxetinehydrochloride hemihydrate, paroxetine mesylate, patiromer calcium,patupilone, pazopanib, pazufloxacin, pazufloxacin mesylate, pefcalcitol,peficitinib, pegylatedapo-filgrastim, pelubiprofen, pemafibrate,pemetrexed disodium, pemirolast, pemirolast potassium, pemirolastsodium, penciclovir, penehyclidine hydrochloride, pentamidine, pentetatecalcium trisodium, pentetatezinc tri sodium, pentetrazol, pentosanpolysulfate sodium, pentostatin, pentoxifylline, peramivir, perampanel,perchlozone, peretinoin, perflenapent, perflubronemulsion,perfluorooctyl bromide, pergolide, perhexiline maleate, perifosine,perindopril, perindopril arginine, perospirone, pevonedistat,pexidartinib, PhagoBioDerm, phenchlobenpyrrone, phenethylisothiocyanate, phenoxybenzamine hydrochloride, phentermine, phenterminehydrochloride, phentolamine mesylate, phenylbutyrate, phenylephrine,phenyl ephrine hydrochloride, phenytoin, phosphazid, pibrentasvir,picibanil, picroliv, picropodophyllin, pidotimod, pilocarpine,pilocarpine hydrochloride, pilsicainide, pimasertib hydrochloride,pimavanserin, pimecrolimus, pimobendan, pinocembrin, pinometostat,pioglitazone, pioglitazone hydrochloride, pipamperone, pipecuronium,piperacillin, piperacillin sodium, piperaquine, piperaquine phosphate,piperidone hydrochloridum, piperine, piperphentonamine, piracetam,pirarubicin, pirfenidone, phmenol, piromelatine, pirotinib, piroxicam,piroxicambetadex, pitavastatin, pitavastatin calcium, pitolisant,pixantrone, plazomicin, pleconaril, plerixafor, plinabulin, pocapavir,hydromorphone, podofilox, polaprezinc, polmacoxib, polydatin,polyoxidonium, pomaglumetad methionil, pomalidomide, ponatinib,ponesimod, porfimer sodium, posaconazole, posiphen, potassiumbicarbonate, potassium citrate, potassium clavulanate, poziotinib,pracinostat, pradefovir, pralatrexate, pramipexole, pramiracetam,pranlukast, pranlukast hydrate, prasterone, prasugrel, pravastatin,prazosin, prednimustine, prednisolone, prednisoloneacetate, prednisolonesodiumphosphate, prednisone, pregabalin, prempro, presatovir,pretomanid, previdersin, prexasertib, pridopidine, prilocaine,pritelivir, procaterol hydrochloride, prochlorperazine,prochlorperazinemaleate, profezyme, progesterone, progestogen,progestogendienogest, proguanil, promethazine, promitil, propafenone,propagermanium, propofol, propranolol, propranolol hydrochloride,prostat, proxodolol, prucalopride, prulifloxacin, prurisol,prussianblueinsoluble, pseudoephedrine, pseudoephedrine hydrochloride,puerarin, puquitinib mesylate, pyrazinamide, pyridoxaminedihydrochloride, pyridoxine hydrochloride, pyrimethamine, pyronaridine,pyrroltinibmaleate, quazepam, quetiapine fumarate, quetiapine,quinagolide hydrochloride, quinapril hydrochloride, quinidine sulfate,quinine sulfate, quinupristin, quisinostat, quizartinibdi hydrochloride,rabeprazole, rabeprazolesodium, rabeximod, racecadotril, radezolid,radotinib, ralfinamide, ralimetinib, ralinepag, raloxifene, raltegravir,raltitrexed, ramatroban, ramelteon, ramipril, ramosetron, ranitidine,ranitidine bismuth citrate, ranolazine, rasagiline, ravidasvirhydrochloride, raxatrigine, rebamipide, rebastinib, reboxetine,reboxetine mesylate, recilisib sodium, recoflavone, redaporfin,ibuprofen, naproxen, glycopyrroniurn bromide, refametinib, regorafenib,relebactam, relenopride, relugolix, remeglurant, remifentanil,remifentanil hydrochloride, remimazolam, remimazolam tosylate,remogliflozin etabonate, repaglinide, reparixin, repirinast amlexanox,chlorcyclizine hydrochloride, bucillamine, guanabenz, mazindol,naltrexone, nitisinone, ondansetron, phacetoperane, retigabine,rosiglitazone, sodium phenylbutyrate, resiniferatoxin, resiquimod,resminostat, resveratrol, retagliptin, retapamulin, retigabine,retinoicacid, retosiban, revaprazan, revefenacin, reviparin sodium,rhein, rhenium-186 etidronate, ribavirin, ribociclib, ricolinostat,ridinilazole, ridostin, rifabutin, rifampicin, rifamycin, rifapentine,rifaximin, rigosertib sodium, rilapladib, rilpivirine, rilpivirinehydrochloride, riluzole, rimantadine, rimeporide, rimexolone, riociguat,ripasudil hydrochloride hydrate, risedronate sodium, risperidone,ritonavir, rivaroxaban, rivastigmine, rivipansel sodium, rizatriptan,rizatriptan benzoate, rmulation, rociletinib, roflumilast, rokitamycin,rolapitant, romurtide, ronacaleret, roneparstat, ronopterin, ropinirole,ropinirole hydrochloride, ropivacaine, rosebengal sodium, rosiglitazone,rosiglitazone maleate, rosiglitazone sodium, rostafuroxin, rosuvastatin,rosuvastatin calcium, rotigotine, rovatirelin, roxadustat,roxithromycin, rubitecan, rucaparib phosphate, rufinamide, rufloxacin,rupatadine, ruxolitinib, S-(−)-ornidazole phosphate disodium,sabarubicin, sacubitril, safinamide, salbutamol, salbutamol sulfate,salicyclic acid, salmeterol, salmeterol xinafoate, salubrinal,salvicine, samarium(153Sm) lexidronam, samidorphan, S-amlodipinenicotinate, sapacitabine, sapropterin, sapropterin dihydrochloride,saquinavir, saracatinib, sarecycline, saroglitazar, sarpogrelatehydrochloride, savolitinib, saxagliptin, scopolamine, scorpionvenom,omega-3 polyunsaturated fatty acid, secnidazole, segesterone acetate,selegiline, selegiline hydrochloride, selepressin, selexipag,seliciclib, selinexor, selisistat, selumetinib, selurampanel,sepranolone, seratrodast, serlopitant, sertaconazole, sertaconazolenitrate, sertindole, sertraline, sertraline hydrochloride, setipiprant,sevelamer carbonate, sevelamer hydrochloride, seviteronel, sevoflurane,sevuparin sodium, sibutramine maleate, sibutramine mesylate, sildenafil,sildenafil citrate, silibinin dihydrogen succinate, silmitasertib,silodosin, silver sulfadiazine, simeprevir, simmitecan hydrochloride,simotinib hydrochloride, simvastatin, sinotecean, siponimod, sirolimus,sitafloxacin, sitagliptin, sitagliptinphosphate, sivelestat, sizofiran,smilagenin, S-modafinil, sobuzoxane, sodium aescinate, sodium ascorbate,sodium benzoate, sodium bicarbonate, sodium chromoglycate, sodiumferricgluconate complex, sodium glycididazole, sodium gualenate, sodiumhyaluronate, sodium ibandronate, sodium nitrate, sodium nitrite, sodiumoxybate, sodium phenylacetate, sodium phenylbutyrate, sodiumpolysulthionate, sodium prasteronesulfate, sodium pyruvate, sodiumtaurocholate, sodium thiosulfate, sodium zirconiumcyclosilicate,sofosbuvir, sofpironium bromide, solabegron, solifenacin, solithromycin,sonidegib, sonoli sib, sophocarpine, sophoridine hydrochloride,sorafenib, sorbitol, sotagliflozin, sotirimod, sotrastaurin, sotylize,sovaprevir, sparfloxacin, sparsentan, spebrutinib, spirapril,spironolactone, squalamine, stannsoporfin, stavudine, S-tenatoprazole,stepronin, stiripentol, streptozocin, strontium malonate, strontiumranelate, succinic acid, sucralfate, sucroferric oxyhydroxide,sufentanil, suftalanzinc, sugammadex, sulbactam, sulbactam sodium,sulcardine sulfate, sulfamethoxypyrazine, sulfasalazine, sulfatinib,sulfonylurea, sulforaphane, sulfotanshinone sodium, sulindac,sulodexide, sulphamethoxazole, sulthiame, sumatriptan, sumatriptansuccinate, sunitinib, sunstone, suplasyn, suplatast tosilate, suraminsodium, verapamil hydrochloride, rilpivirine, sutezolid, suvorexant,tacalcitol, tacrine, tacrolimus, tadalafil, tafamidis, tafenoquine,tafluprost, tafoxiparin sodium, taladegib, talaporfin, talazoparib,talipexole, taltirelin, tamibarotene, tamoxifen, tamsulosin, tamsulosinhydrochloride, tandospirone, tanespimycin, tapentadol, tarafenacin,tarenflurbil, tarloxotinib bromide, taselisib, tasimelteon, tasquinimod,tavaborole, tavilermide, tazarotene, tazemetostat, tazobactam,tazobactam sodium, tebipenem pivoxil, tecarfarin, tecovirimat,tectorigenin sodiumsulfonate, tedisamil, tedizolid phosphate,tefinostat, tegafur, tegaserod, teicoplanin, telaprevir, telapristoneacetate, telatinib, telbivudine, telithromycin, telmisartan,telotristatetiprate, temanogrel, temocapril, temoporfin, temozolomide,temsirolimus, tenalisib, tenapanor, teneligliptin, tenofovir,tenofoviralafenamide, tenofovirdipivoxil fumarate, tenofovir disoproxilaspartate, tenofovir disoproxil fumarate, tenoxicam, tepotinib,teprenone, terameprocol, terazosin, terbinafine, terbinafinehydrochloride, terguride, teriflunomide, tesevatinib, tesofensine,testosterone, testosterone undecanoate, tetrabenazine, tetracaine,tetracaine hydrochloride, tetrahydrocannabidiol, tetrathiomolybdate,tetryzoline, tezacaftor, thalidomide, theliatinib, theophylline,therapeutic, thiazide, thienorphine hydrochloride, thiotepa, thrombin,thromboreductin, thyroxine, tiagabine, tianeptine, tibolone, ticagrelor,ticlopidine, tigecycline, tiludronatedi sodium, timolol, timololmaleate, tindamax, tinidazole, tinzaparin sodium, tioconazole,tiopronin, tiotropium bromide, tiotropium bromide monohydrate,tipelukast, tipepidine hibenzate, tipifarnib, tipiracil hydrochloride,tipranavir, tirapazamine, tirasemtiv, tirilazad, tirofiban, tirofibanhydrochloride, tivantinib, tivozanib, tizanidine, tobramycin,tocofersolan, tocoretinate, tofacitinib, tofogliflozin, tolcapone,tolimidone, tolperisone, tolterodine, tolterodine tartrate, tolvaptan,tonabersat, topiramate, topiroxostat, topotecan, topotecanhydrochloride, torasemide, toreforant, toremifene, tosedostat,tosufloxacin, totrombopag, tozadenant, trabectedin, trabodenoson,tradipitant, tramadol, tramadol hydrochloride, trametinib, trandolapril,tranexamic acid, tranilast, transcrocetinate-sodium, transepithelialriboflavin, trantinterol hydrochloride, travoprost, trazodone,trehalose, trelagliptin succinate, treosulfan, treprostinil,treprostinil diolamine, tretinoin, triamcinolone acetonide, triapine,triazolam, tribendimidine, trichlormethiazide, triciribine,triclabendazole, triclocarban, trientine hydrochloride, trifarotene,trifluridine, triflusal, triheptanoin, trilostane,trimebutine3-thiocarbamoyl-benzenesulfonate, trimebutine tosylate,trimegestone, trimethoprim, trimetrexate, trinitrate, tripotassiumdicitratobismuthate, trofinetide, tropicamide, tropisetron,trospiumchloride, trovafloxacin, troxipide, tucatinib, tulobuterol,tylerdipinehydrochloride, ubenimex, ubidecarenone, ubrogepant, udenafil,ulinastatin, ulipristal, ulixertinib, ulobetasol, umeclidinium,umeclidinium bromide, upamostat, uprosertib, uracil, urapidil,uridinetriacetate, uroacitides, ursodeoxycholic acid, ursolicacid,vaborbactam, vadadustat, valaciclovir, valaciclovir hydrochloride,valbenazine, valdecoxib valganciclovir, valomaciclovir stearate,valproic acid, valrubicin, valsartan, valsartan trisodiumhemipentahydrate, vancomycin, vancomycin hydrochloride, vandetanib,vaniprevir, vanoxerine, vapendavir, vardenafil hydrochloride,varenicline, varithena, varlitinib, vatiquinone, vavelta, veliparib,velpatasvir, velusetrag, vemurafenib, venetoclax, venlafaxine,ventafaxine hydrochloride, vepoloxamer, verapamil, verapamilhydrochloride, verdinexor, veregen, vericiguat, verinurad, vernakalant,vernakalant hydrochloride, verosudil, verteporfin, verubecestat,verubulin, vesatolimod, vesnarinone, vibegron, vicagrel, vigabatrin,vilanterol, vilanterol trifenatate, vilaprisan, vilazodone,vildagliptin, vincristine sulfate, vinflunine, vinorelbine, vinpocetine,vintafolide, viralym-C, vismodegib, vistusertib, vitamin E nicotinicate,vizomitin, voglibose, volasertib, volixibat potassium ethanolatehydrate, vonoprazan fumarate, vorapaxar, voriconazole, vorinostat,vortioxetine, vortioxetine hydrobromide, vosaroxin, voxilaprevir,warfarin, xemilofiban, yimitasvir, yonkenafil, zabofloxacin,zafirlukast, zalcitabine, zaleplon, zaltoprofen, zamicastat, zanamivir,zemiStatin, Z-endoxifen hydrochloride, zibotentan, zidebactam,zidovudine, zileuton, zincacetate, zinostatin stimalamer, ziprasidone,zofenopril, zogenix, zoledronate D,L-lysinemonohydrate, zoledronatedisodium, zoledronic acid, zoliflodacin, zolmitriptan, zolpidem,zolpidem tartrate, zonisamide, zopiclone, zotepine, zucapsaicin,zuclopenthixol, and zuretinol acetate, including combinations thereof.

In some embodiments, the medicament can be provided in one or more formsthat could exhibit diminished efficacy or stability during the formationof a dosage form, particularly if the medicament is exposed to theprinting fluid and/or interacts with other components within thebound-powder matrix. In some embodiments, the API compound itself issensitive to process conditions for constructing the dosage form. Inanother embodiment, the medicament can be provided in the form ofengineered particles made via spray drying, coating, granulation,chemical complexation, co-crystallization, or combinations thereof. Insome embodiments, the medicament can be chemically incompatible with oneor more excipients comprised within a container body or lidding body.Non-limiting examples of such coatings can include taste-masking agents,as well as controlled-release agents or extended-release agents, whichcan be utilized to delay dissolution of the medicament until after thedisintegrated dosage form is ingested. In some embodiments, the APIcompound or the medicament as a whole can be sensitive to one or more ofmoisture, liquid, light, and/or elevated temperature.

Without being limited by a particular theory, sensitivity to one or moreprocess conditions or components within the bound-powder matrix cannegatively impact the physical or chemical instability of themedicament; the dissolution, release, or efficacy of the API compound;and/or organoleptic or other physical properties of the dosage form. Asa result, the time required to develop dosage forms containing suchsensitive materials is often extensive and laborious. However, inanother embodiment, the research and development time for dosage formscomprising condition- or process-sensitive API compounds or medicamentscan be decreased by dispensing them into pre-formed container bodies,and enclosing them with a pre-formed lidding body, according to any ofthe methods for forming a dosage form described herein. Use of suchpre-formed container bodies and lidding bodies allows for the filling ofmedicament (and optionally other components) under process conditionsthat differ from those used to make the container bodies and liddingbodies. This approach can be used to avoid liquid exposure, ovenexposure, or other process condition that is undesirable for certainAPIs or medicaments. In one non-limiting example, a pre-formed containerbody and lidding body are used to allow dry filling of medicament in apreferred solid-state form as a co-crystal, thereby avoiding dissolutionof the co-crystal and potential subsequent recrystallization as one ormore undesired crystal forms or as amorphous material subject to formchange. In another non-limiting example, a pre-formed container body andlidding body are used to allow dry filling of an effervescent materialincorporating one or more medicaments, thereby avoiding liquid contactthat would inadvertently trigger effervescent reaction duringprocessing. In another non-limiting example, a pre-formed container bodyand lidding body are used to allow dry filling of a coated API ormedicament, thereby avoiding liquid exposure and/or oven exposure thatmay compromise the function of the coating, such coating functionincluding taste-masking, controlled- or modified- or extended-release,physical isolation for chemical stability reasons, or otherpharmaceutical purpose as recognized in the art.

In another non-limiting example, a pre-formed container body and liddingbody are used to allow dry, ambient temperature filling of an API ormedicament provided in the form of an amorphous solid dispersion (ASD),thereby avoiding undesired liquid exposure and/or oven exposure that maycompromise the function of the ASD. As is recognized in the relevantart, ASDs may be used to improve bioavailability of compounds with pooraqueous solubility, such as compounds in Class II and/or Class IV of theBiopharmaceutics Classification System (BCS). Generally, ASDs aremanufactured by either a solvent-based approach or a fusion-basedapproach, the objective being to maintain the drug in an amorphousstate, retain drug stability characteristics, and create a free-flowingpowder that can be easily processed using conventional dosage formmanufacturing technologies. In particular, fusion-based approaches caninclude the thermo-kinetic processing of hot melt extrudates to formmulti-particulate formulations which can be tailored to provide suchproperties as modified release (e.g. extended release, controlledrelease, and other release profiles), enhanced bioavailability, tastemasking, improved solubility, and/or medicament stabilization. Methodsand apparatuses for producing multi-particulate formulations with suchproperties are described, for example, in U.S. Pat. Nos. 9,050,254 and10,132,565, as well as U.S. Patent Publication Nos. 2011/0014295 and2021/0038520, the disclosures of which are herein incorporated byreference in their entireties.

In another non-limiting example, a pre-formed container body and liddingbody are used to allow dry, ambient temperature filling of an API ormedicament provided in the form of a melt extrudate or other engineeredparticles initially formed via melt extrusion, thereby avoidingundesired liquid exposure and/or additional thermal exposure that maycompromise one or more functions of the melt extrudate or otherengineered particles initially formed via melt extrusion.

In another non-limiting example, a pre-formed container body and liddingbody are used to allow dry, ambient temperature filling of anorally-available protein, peptide, monoclonal antibody, vaccine, orother biologic, thereby avoiding undesired liquid exposure and/or ovenexposure that might compromise the physical or chemical stability, orthe biological activity, of the protein, peptide, monoclonal antibody,vaccine, or other biologic.

In another embodiment, the medicament can be a chemical compoundapproved by the FDA or similar governing agency for administering to asubject as part of a clinical trial. In another embodiment, the solidmedicament can be a placebo material intended to mimic the taste,texture, and overall experience of a rapidly-orodispersible dosage formcontaining a medicament, but without having a pharmacologic effect.

In another embodiment, a dissolvable barrier material can be depositedinto a cavity prior to depositing the one or more solid medicaments, toinhibit or prevent migration of the one or more medicaments into thebound-powder material comprising the dosage form. As with the powder andbinder materials, dissolvable barrier materials can also be ingested anddisperse in aqueous solution at a similar rate, or faster rate, comparedto the porous bound powder matrix materials comprising the tablet.Non-limiting examples of dissolvable barrier materials can be selectedfrom the group consisting of: mannitol, sorbitol, xylitol, lactitol,erythritol, isomalt, povidone, copovidone, hydroxypropylcellulose,hydroxypropylmethylcellulose, carboxymethylcellulose, gelatin, casein,agar, guar gum, gellan gum, xanthan gum, locust bean gum, alginate,carrageenan, hydroxypropyl starch, pre-gelatinized starch, poloxamer,polyethylene glycol, polydextrose, or polyvinyl alcohol, includingderivatives and/or combinations thereof.

In another embodiment, a pre-determined mass of one or more solid,particulate payload material(s), for example, a particulate medicament,can be deposited into and contained within the cavity. A pre-determinedamount, by mass or volume, of particulate payload material can bemechanically dosed and/or metered into the depression by any means knownin the art, non-limiting examples of which are described in U.S. Pat.Nos. 9,409,699 and 9,828,119, and US Patent Publications 2017/0322068and 2018/0031410, the disclosures of which are incorporated by referencein their entireties. In another embodiment, the mass of the one or moremedicaments contained within the dosage form, whether deposited into thecavity or interspersed within the dosage form's interconnected matrix,can be any one of at least 1 microgram, or at least 1 milligram, or atleast 5 milligrams, or at least 10 milligrams, or at least 25milligrams, or at least 50 milligrams, or at least 75 milligrams, or atleast 100 milligrams, or at least 200 milligrams, or at least 250milligrams, or at least 300 milligrams, or at least 400 milligrams, orat least 500 milligrams, or at least 600 milligrams, or at least 700milligrams, or at least 800 milligrams, or at least 900 milligrams, orat least 1 gram, or at least 2 grams, or at least 3 grams, or at least 4grams, or at least 5 grams, or at least 10 grams, and up to 10 grams, orup to 5 grams, or up to 1 gram, or up to 500 milligrams, or up to 250milligrams, or up to 100 milligrams, up to 10 milligrams. In anotherembodiment, the mass of the one or more solid medicaments deposited intoa cavity or interspersed within the dosage form's interconnected matrixcan be in a range between and inclusive of any of the values listedabove, including but not limited to: at least 1 microgram and up to 10grams; or at least 1 milligram and up to 1 gram; or at least 1 milligramand up to 10 milligrams; or at least 10 milligrams and up to 100milligrams; or at least 100 milligrams and up to 200 milligrams; or atleast 100 milligrams and up to 500 milligrams.

In another embodiment, which may be used in combination with any one ormore of the embodiments described above and herein, the volume of aparticulate payload material comprising one or more medicamentsdispensed into the cavity of a rapidly-orodispersible container can besufficient to fill the cavity. As shown in FIG. 13 in the left side ofthe illustration, the particulate payload material 60 has a top surface61 that is planar with the upper surface 62 of the peripheral wall 33 tocompletely fill the cavity 34. In another embodiment, which may be usedin combination with any one or more of the embodiments described aboveand herein, shown in the right side of the illustration of FIG. 13 , thevolume of the particulate payload material 60 can be sufficient topartially fill the volume of the cavity 34, such that the top surface 61of the particulate payload material 60 is below the level of the uppersurface 62 of the peripheral wall 33. A cavity partially-filled with aparticulate payload material 60 can be subsequently filled by dispensingone or more filler materials 63 on top of the particulate payloadmaterial 60, until the top surface 64 of the filler material 63 issubstantially planar with the upper surface 62 of the peripheral wall33, as shown in FIG. 14 . In another embodiment, the one or more fillermaterials can be an unbound form of the powder material used to form thebound-powder matrix. In another embodiment, the one or more fillermaterials can be added to provide a physical and/or chemical barrierbetween the medicament and the external environment outside of thedosage form, prior to closing off the cavity within an interior portionof the completed dosage form. According to the present invention, theone or more filler materials can be selected from the group consistingof calcium carbonate, calcium lactate, calcium phosphate, calciumsilicate, calcium sulfate, cellulose, dextrose, erythritol, isomalt,lactitol, lactose, magnesium carbonate, magnesium oxide, maltodextrin,maltose, mannitol, microcrystalline cellulose, polyethylene glycol,sodium bicarbonate, sodium carbonate, sodium chloride, sorbitol, starch,sucrose, talc, trehalose, and xylitol, and combinations thereof. In anon-limiting example, a bulk powder material and/or a filler materialcan consist of 90% (w/w) calcium carbonate and 10% (w/w) povidone.

In another embodiment, the filler material can be a super disintegrant.As used herein, a “superdisintegrant” is a material or composition whichcan be comprised within a dosage form to enhance its orodispersibilityupon contacting a liquid, such as saliva or water. Without being limitedby a particular theory, it is believed that superdisintegrant materialsswell in the presence of water. When a superdisintegrant situated withinan interior cavity is exposed to the liquid upon the partialdisintegration of the dosage form, the swelling of the superdisintegrant can create an internal pressure within the cavity andaccelerate the disintegration of the remaining portions of the dosageform. Non-limiting examples of superdisintegrants includecarboxymethylcellulose sodium, croscarmellose sodium, sodium starchglycolate, and crospovidone. A superdisintegrant comprised within afiller material can be selected from the group consisting of any of thesuperdisintegrants listed above, including combinations thereof.

In another embodiment, a rapidly-orodispersible dosage form can beconstructed from any of the containers described above, by covering theupper surface of the container and the one or more medicaments,excipients, dissolvable barrier materials, and/or filler materialscontained within the one or more cavities. Each of the cavities becomesisolated within the interior portion of the dosage form, both from othercavities and from the environment outside of the dosage form.

In a non-limiting example, and in another embodiment, an upper layer ofpowder material 70 having a substantially-uniform thickness can beformed upon the coplanar surface formed by the upper surface 62 of theperipheral wall 33 and the top surface 61 of particulate payloadmaterial 60, as shown in the left side of the illustration of FIG. 15 .As shown in the right side of the illustration of FIG. 15 , droplets 21of a printing liquid can be applied to the upper layer of powdermaterial 70, in a pattern and volume to form a dosage form having abound-powder upper layer 72 atop the cavity filled with particulatepayload material 60; forming a unitary dosage form 80 within thedepression 10 as shown in FIG. 16 . The steps of forming an upper layerof powder material and dispensing a printing liquid atop the cavity canoptionally be performed one or more additional times, in forming theunitary dosage form 80.

Partially-Enclosed Dosage Forms

In an embodiment of the invention, a unitary, partially-enclosed dosageform is provided, having an internal cavity, and having a port openingwithin and through the container body (for example, through the base orthe peripheral wall) or a lid portion that encloses the container body.The port opening is in fluid communication with the one or more cavitiesformed within the container body. The port opening is typically aportion of the lid or the container body where the particulate powdermaterial was left unbound (for example, unprinted with printing liquid)during the forming of the bounder powder matrix of the lid or containerbody. Once the lid and container body have been formed, any unboundpowder material contained within the interior cavity(ies) of thecontainer body can be evacuated through the port opening.

A port opening can be of any formable shape, although circular or ovalshapes preferred. The cross-sectional size of the port opening istypically sufficient in effective size or diameter to evacuate theunbound powder material from the interior cavity by fluidizing orpouring the unbound powder material out through the port opening, andsufficient to permit filling the evacuated interior cavity with apayload material. After a payload material is placed within the interiorcavity, along with any optional filler material, the port opening can beclosed and sealed as discussed herein. The effective size or diameter ofthe port opening can be as minimal in size or diameter as possible tosimplify or improve the subsequent closing and/or sealing of the portopening, once most or all of the unbound powder material has beenevacuated, and the payload material deposited into the internal cavityof the dosage form.

FIG. 17 shows a sectional view of the container body 31 formed within adepression 10, as shown in FIG. 6 , having a cavity 34 filled withunbound build powder material 50, and upon which one (or more)incremental upper layer 70 of build powder material is formed having asubstantially uniform thickness. As shown in the left side of FIG. 18 ,a printing liquid 21 is deposited onto preselected portions of theincremental upper layer 70 of build powder material, though avoiding thedepositing of the printing liquid is an area 84, forming a printed orwetted layer 83 that surrounds the unprinted area 84. In the right sideof FIG. 18 , wetted layer 83 forms the bound powder matrix of a lid 85for the container body, having an area of unbound powder material toform a port opening 86, typically located proximate at or near thecenter of the lid 85.

In most circumstances, the effective opening size or diameter of theport opening is typically from about 1 millimeter (mm), and up to about5 mm, and may be about 2 mm to 4 mm, about 2 mm to 3 mm, about 3 mm to 4mm, and about 4 mm to 5 mm. The relative effective size or diameter of aport opening formed into a lid of a dosage form, or a base of acontainer body, is less than 50%, more typically less than 25%, and evenmore typically less than 15%, the effective size or diameter of the lidor base of the container.

The resulting unitary, partially-enclosed dosage form comprises thecontainer body 31 having an internal cavity 34 filled with unbound buildpowder material 50, covered with a unitary lid 85 of bound powder matrixmaterial and having the port opening 86. FIG. 19 shows an evacuationsystem V for evacuating or removing the unbound build powder material 50from within the cavity 34, through the port opening 86 in the lid 85. Inthe illustrated embodiment, the evacuation system is illustrated as avacuum system which draws air and the fluidizing unbound build powdermaterial 50 from within the cavity 34. A distal tip of a tube 87connected to the vacuum system V can be inserted into port opening 86 inthe lid 85 to assist in evacuating most or all of the unbound buildpowder material 50, to leave an empty or substantially empty cavity 34.The inlet opening in the tube 87 should be larger than the largestparticle size of the particulate build powder material.

After most or all of the unbound build powder material 50 is evacuatedfrom the cavity 34, a payload material 60 can be deposited into theevacuated cavity. FIG. 20 shows a means for partially or completelyfilling the empty cavity 34 through the port opening in the lid, with apayload material 60. The payload material can be deposited into thecavity 34 by any well-known means, such as a pipette 88 as illustrated,or an injection needle, which can be inserted through the port opening86 and into the cavity 34 to avoid spillage or loss of the payloadmaterial. The payload material can be any of the solid, particulate,liquid, semi-solid or engineered particles and materials describedherein. In some embodiments, after the payload material 60 has beendeposited into the cavity, a filler material that is typically inertwith the payload material, can be deposited to fill the remaining volumeof the cavity 34. In some embodiments, only a small portion of theunbound build powder material 50 can be withdrawn from the cavity 34, asshown in FIG. 20 , the small portion by volume being sufficient toprovide space for a small amount or volume of a payload material 60.

After the payload is deposited into the cavity of the partially-encloseddosage form, the port opening 86 in the lid 85 can be closed and sealedto prevent the payload and any remaining unbound build powder materialfrom escaping. FIG. 21 shows a plug 89 filling and sealing the portopening 86. The sealing material of the plug 89 can be a solid orsolidifying material, and preferable a water-soluble and ingestiblematerial. A preferred material is a solid or waxy material at normalroom or storage temperatures, and meltable at elevated temperatures toflow into and seal the edges of the port opening 86. Non-limitingexamples of a sealing material are fats, water-soluble polymers,polyethylene glycol, carbohydrates and carbohydrate alcohols, includingany one or more thermal binding materials as described herein.

Separate Container and Lid

In another embodiment, rather than printing one or more bound-powderupper layers to form a container body with a lid as a single, contiguousmatrix, a container 31 can be formed and then filled with a payloadmaterial 60 and optionally filler material 63, and a separately-formedrapidly-orodispersible lid can be placed and secured upon the uppersurface of a rapidly-orodispersible container 31. Processes for forminga rapidly-orodispersible tablet from separately-formed container- andlidding bodies are described herein.

Forming a lidding body separately from the container body can beadvantageous because it enables the rapidly-orodispersible tablet to beconveniently constructed and handled within different areas of the samefacility, or between multiple facilities, without having to form theentire tablet at one place or facility, or at the same time. In anon-limiting example, a set of container bodies and lidding bodies canbe formed separately in a first facility and subsequently packaged as akit and shipped to a second facility. At the second facility, one ormore payloads can be dispensed into the interior cavity of the containerbody, and the lidding body can be secured to the container body, to formthe rapidly-orodispersible tablet. In a further embodiment, the formedcontainer and lidding bodies can be stored for a period of time selectedfrom the group consisting of hours, days, weeks, months, or years, priorto dispensing the one or more payloads into an internal cavity andsecuring the container body and lidding body together to form a tablet.

In a non-limiting example, a kit consisting of a container body and alidding body can be provided to a point-of-care facility, such as ahospital, clinic, nursing home, or pharmacy. In some embodiments, thecontainer body can be filled with a payload, particularly payloadscomprising one or more medicaments, immediately upon the container body,lidding body, and payload arriving at the point-of-care facility. Inother embodiments, the container body and/or lidding body can be storedat the point-of-care facility for a length of time, until a particularrapidly-orodispersible tablet is required or prescribed.

In another embodiment, the lidding body can be formed to have acomplementary shape and size relative to the upper surface and/or theinterior cavity of the container body. In another embodiment, thelidding body can be formed to completely cover the interior cavity whenit is secured to the container body, preventing the accidental orincidental release of the solid medicament from therapidly-orodispersible tablet and potential damage from the tablet'sexternal environment. In a further embodiment, the lidding body can beformed so it also covers the upper surface of the container body. As anon-limiting example, and in another embodiment, a lidding body can beformed so it has the same diameter as the upper surface of a cylindricalcontainer body, to form a cylindrical rapidly-orodispersible tablet. Inanother embodiment, the lidding body can be formed so it extends beyondthe upper surface of the container body. In another embodiment, thelidding body can be formed so it extends beyond the upper surface of thecontainer body and along one or the external surface of the containerbody peripheral wall. Non-limiting examples of such lidding bodies, andtheir complementary shapes relative to the container body are describedin further detail, below.

In another embodiment, the lidding body can be formed to have anydesired height relative to the height of the container body. In anotherembodiment, the lidding body can be formed to have a height that isequal or less to the height of the container body. In anotherembodiment, the ratio of the height of the lidding body relative to thecontainer body can be selected from the group consisting of: less than1:1; less than 0.95:1; less than 0.9:1; less than 0.85:1; less than0.8:1; less than 0.75:1; less than 0.7:1; less than 0.65:1; less than0.6:1; less than 0.55:1, less than 0.5:1; less than 0.45:1, less than0.4:1; less than 0.35:1, less than 0.3:1; less than 0.25:1, less than0.2:1; less than 0.15:1; and less than 0.1:1. In another embodiment, thelidding body can be formed to have a height that is equal or greaterthan the height of the container body. In another embodiment, the ratioof the height of the lidding body relative to the container body can beselected from the group consisting of: greater than 1:1; greater than1.05:1; greater than 1.1:1; greater than 1.15:1; greater than 1.2:1;greater than 1.25:1; greater than 1.3:1; greater than 1.35:1; greaterthan 1.4:1; greater than 1.45:1; greater than 1.5:1; greater than1.55:1; greater than 1.6:1; greater than 1.65:1; greater than 1.7:1;greater than 1.75:1; greater than 1.8:1; greater than 1.85:1; greaterthan 1.9:1; greater than 1.95:1; and greater than 2:1. Non-limitingexamples of the such lidding bodies, and their complementary sizesrelative to the container body are described in further detail, below.

In another embodiment, the lidding body can have a planar undersurfaceformed to have the same size and geometric shape as the planar uppersurface of the container body peripheral wall. The selection of suchgeometric shapes is generally described above. Several non-limitingexamples of lidding bodies formed to have a planar undersurface having acomplementary size and shape relative to a planar upper surface of acorresponding container body are illustrated in FIGS. 22 and 23, 24 and25, and 26 and 27 , including lidding bodies with circular, elliptical,and rectangular undersurfaces that can be secured to container bodieshaving corresponding circular, elliptical, and rectangular uppersurfaces, respectively. FIGS. 22 and 23 show exploded and perspectiveviews of a spherocylindrical dosage form 130A assembled from a liddingbody 131A with a circular undersurface 132A and a container body 133Awith a circular upper surface 134A. FIGS. 24 and 25 show exploded andperspective views, respectively, of an ovoid dosage form 130B assembledfrom a lidding body 131B with an elliptical undersurface 132B and acontainer body 133B with an elliptical upper surface 134B. FIGS. 26 and27 show exploded and perspective views, respectively, of a dosage form130C with a cuboid shape, assembled from a lidding body 131C with arectangular undersurface 132C and a container body 133C with arectangular upper surface 134C. In other embodiments, any of the liddingbodies 131A or 131B illustrated in FIGS. 22-25 and having an internalcavity can optionally be constructed to have a solid interior portion,similar to lidding body 131C in FIGS. 26 and 27 .

In another embodiment, the lidding body can be secured to the containerbody by one or a combination of securing, including one or more of anadhesive material applied to one or both of the lidding body and thecontainer body, a mechanical securement formed into or associated withone or both of the lidding body and the container body, and a frictionalengagement between the lidding body and the container body, includingcombinations thereof. By any means, and in another embodiment, once thelidding body and the container body are secured together, the resultingdosage form can have the ability to withstand shearing, twisting, and/orimpact forces that may cause the lidding body and the container body toinadvertently or incidentally separate from each other prior to beingadministered to a user.

In another embodiment, the lidding body and the container body can besecured together adhesively, with an adhesive material disposed at theconfronting and contacting surfaces of the lidding body and thecontainer body. Generally, a suitable adhesive material can have thestrength to withstand any of the forces described above, while at thesame time being non-toxic to a user who is ingesting therapidly-orodispersible dosage form. In another embodiment, such adhesivematerial can be selected from the group consisting of mannitol,sorbitol, xylitol, lactitol, erythritol, isomalt, povidone,polyvinylpyrrolidone (PVP, copovidone), hydroxypropylcellulose,hydroxypropylmethyl-cellulose, carboxymethylcellulose, gelatin, casein,agar, guar gum, gellan gum, xanthan gum, locust bean gum, alginate,carrageenan, hydroxypropyl starch, pre-gelatinized starch, poloxamer,polyethylene glycol, polydextrose, or polyvinyl alcohol, includingderivatives thereof and/pr combinations thereof.

In a further embodiment, the adhesive material can be a material thatbecomes an adhesive upon being heated or thermally activated to atemperature above at least the softening point of the material, andoptionally being heated at or above the melting point of the material.The adhesive material can be conductively heated by placing a heatingelement, such as a temperature-controlled soldering iron, in directcontact with the juncture of the lidding body and/or container body,proximate their confronting and contacting surfaces. In anotherembodiment, the adhesive material can be radiantly heated by directingradiant heat, such as infrared or laser light, at the juncture of thelidding body and/or container body, proximate their confronting andcontacting surfaces.

Non-limited examples of adhesive materials that can bethermally-activated are mannitol, sorbitol, xylitol, lactitol,erythritol, isomalt, povidone, copovidone, hydroxypropylcellulose,poloxamer, polyethylene glycol, and polyvinyl alcohol. In a non-limitingexample, a thermally-activatable adhesive material, such as mannitol,can be individually comprised within the interconnected matrix of thecontainer body and/or the lidding body, wherein a rapidly-orodispersibletablet can be formed by applying heat to one or more points of contactbetween the lidding body and container body, sealing them together.

In a non-limiting example, adhesive material can be a componentparticulate compound or composition contained within the build powdermaterial, and in some embodiments, the adhesive material can also be abinder material contained within the build powder material, includingany of the compounds identified as a binder material herein. Onenon-limiting example of an adhesive material contained in the buildpowder is mannitol. The bound powder matrices of both the container bodyand the lidding body can contain particles of the binder materialdistributed throughout the matrices. By applying heat (conductively,convectively, or radiantly) to one or more junction points where thesurfaces of the lidding body confront and contact the container body, aportion of the binder material disposed at the contacting surfaces ofthe bound powder matrix of either (or both) the lidding body and thecontainer body can soften or melt and flow into mutual contact with bothsurfaces, adhering the two surfaces together at the one or more junctionpoints. In other embodiments, applying heat (conductively, convectively,or radiantly) continuously along the confronting surfaces of thecontainer body and the lidding body can form a continuous bonded andsealed interface between the two body surfaces.

In a first non-limiting example shown in FIG. 28 , a dosage form can beformed by securing a cylindrical container body 101 with a cylindricallidding body 102. The container body 101 has a circular base 103, and aperipheral wall 104 having an inner diameter d₁ and an outer diameterdz. The peripheral wall 104 extends from the periphery of the base 103and has an external surface 105 and an upper surface 106. The liddingbody 102 has a perimeter edge 107 and a circular undersurface 111 thathas a diameter, d₃, that is the same or greater than the outer diameterd₂ of the container 101. As illustrated, the circular undersurface 111of the lidding body 102 and the circular container base 103 are parallelwith each other. A peripheral portion 112 of the lidding body 102contacts the upper surface 106 of the peripheral wall 104, and aninternal portion 113 covers the cavity 110. The cavity, though shown tobe empty for clarity, can advantageously be either partially- orcompletely filled with one or more particulate payload materials,including the medicament(s), at the time the lidding body is applied andsecured to the container body. Unitary tablet forms, as described above,generally require an upper layer of powder material to be applied atop aplanar surface formed by both the upper surface of the containerperipheral wall as well as the particulate payload material(s) insidethe cavity, in order for the upper layer to have a substantially uniformthickness. In contrast, and as described below, the peripheral portionof the lidding body undersurface can be secured solely to the containerbody peripheral wall, without also having to secure the internal portionof the lidding body undersurface. Consequently, a single dosage formwith a standardized set of dimensions and properties can be utilized tocontain any desired dose amount or volume of medicament(s) inside thecavity, including and up to the volume of the cavity itself.

In another embodiment, an adhesive material can be applied onto anysurface of the container body, the lidding body, or both, that forms acontact surface in the assembled dosage form. Using the dosage form ofFIG. 28 as a non-limiting example, an adhesive material can be appliedto either or both of the peripheral portion 112 of the lidding bodyundersurface 111 and the upper surface 106 of the container bodyperipheral wall 104, including selected portions thereof. In anembodiment, the adhesive material can be applied and distributed acrossthe entire contact surface between the lidding body and the containerbody, or it can be applied so it is localized to selected multipleportions or areas of the contact surface. Those skilled in the art candetermine the identity and location of the applied adhesive materialbased on several factors, including but not limited to the desiredhardness, orodispersibility, and stability of the dosage form. In analternative embodiment, when the particulate payload material(s) withinthe container body completely fills the volume of the interior cavityand has a top surface that is planar with the upper surface of thecontainer body peripheral wall, the adhesive material can also beapplied to the top surface 110 of the particulate payload materialand/or the interior portion of the lidding body undersurface. Inembodiments in which the adhesive material is applied to the solidmedicament directly, the adhesive material can be selected so that isinert relative to the solid medicament and does not affect its stabilityand/or pharmaceutical activity.

In another embodiment, the lidding body and/or the container body can beconstructed to have one or more structural features that increase thesurface area of the contact surface between the lidding body and thecontainer body. In an embodiment shown in FIG. 29 , a lidding body 120can be formed to have a projection portion 121 that extends from theundersurface 111. The projection portion 121 has an annular sidewallsurface 122 having a height, h, and a bottom surface 123 having adiameter, d_(3′). In another embodiment, the annular outer surface 122can have any height sufficient to secure the lidding body 120, whileproviding space sufficient within the cavity 110 for the particulatepayload material. Upon placing the lidding body 120 onto the uppersurface 106 of the peripheral wall 104, the projection portion 121extends into the cavity 110 of the assembled dosage form 125, forming anadditional contact surface between the lidding body 120 and thecontainer body 101. In an embodiment, the bottom surface 123 of thesecured projection portion 121 contacts the particulate payload materialinside the interior cavity 110, while in another embodiment, the bottomsurface 123 of the secured projection portion 121 does not contact theparticulate payload material inside the interior cavity 110.

In another embodiment, the diameter, d_(3′), of the projection portion121 can be configured to be identical to. or only very slightly largerthan, the diameter, d₁, of the interior cavity 110 of the container body101, to allow the outer sidewall surface 122 of the projection portion121 to frictionally engage with the inner surface 109 of the upper endof the peripheral wall 104.

In an alternate embodiment, the diameter, d_(3′), of the projectionportion 121 can be configured to be slightly smaller than the diameter,d₁, of the interior cavity, but large enough for the annular outersurface 122 and the inner surface 109 of the peripheral wall 104 toadhere to each other upon the application of an adhesive material. In afurther embodiment, an adhesive material can also be applied to theperipheral undersurface 112 of the lidding body and/or the upper surface106 of the peripheral wall 104.

In various embodiments, the lidding body and the container body can havemating or congruent mechanical features that mechanically or physicallyengage one another, which prevent movement of the lidding body in atleast one direction relative to the container body, other than thelidding body being seated on the container body to close the cavity ofthe container body when assembled. As used herein, the terms,“mechanically engaged” or “physically engaged” mean that a surface oredge of one body is in direct or near contact with a surface or edge ofthe other body to prevent movement in at least one direction. Theengagement of the mating mechanical features can prevent the liddingbody from moving relative to and/or separating away from the containerbody when assembled in one or more of three directions: an axialdirection, illustrated by axial line 100 in FIG. 28 , where the liddingbody can lift upward from the container body; one or more lateraldirection, illustrated as a movement in the x-y plane shown in FIG. 28 ,where the lidding body can slide laterally away, transverse to the axialline 100, in one or more angular directions; and a rotational direction,illustrated as angular rotation c about the axial line 100 in FIG. 28 ,where the lidding body can rotate about the axial line 100.

As a non-limiting example, the lidding body 120 shown in FIG. 29 has aprojection portion 121 that, when assembled, extends from theundersurface 111 partially into the cavity 110 of the container body101, thereby providing a mechanical or physical engagement that preventsa lateral movement of the lidding body relative to the container body inall lateral directions in the x-y plane. By comparison, in the liddingbodies and container bodies illustrated in FIGS. 22-28 , once thelidding body is seated over and assembled with the container body toclose the cavity of the container body, the lidding body can be moved inany of the three directions to separate from the container body: theaxial direction upward, any lateral direction, and the rotationaldirection. In such embodiments, the lidding body and the container bodyare secured or affixed together by some adhesive or unitary mechanism.The fitment of the peripheral edge of the projection portions 121 of thelidding body 120 with inner surface 109 of the upper end of theperipheral wall 104 of the container body 101 maintains the lidding body120 engaged with the container body 101 during subsequent handling,packaging and use of the article.

Generally, a mating or congruent mechanical securement can comprise afirst mechanical element that mates or congruently engages a second oneor more mechanical elements. A non-limiting example of a firstmechanical element can be selected from the group consisting of a tab,ridge, peak, pin, knob, or similar or equivalent extension feature, anda non-limiting example of a second mechanical element can be selectedfrom the group consisting of a valley, notch, cut, slot, thread, orsimilar or equivalent receiving feature. Processes for forming suchmechanical elements as a feature into a bound powder matrix, includingusing 3DP, are well known in the art. In another embodiment, one or morefirst mechanical elements can be formed into the lidding body, while oneor more second mechanical elements can be formed into the containerbody. In another embodiment, the one or more first mechanical elementscan be formed into the container body, while the one or more secondmechanical elements can be formed into the lidding body. In anotherembodiment, a lidding body and a container body within the same tabletcan each contain first and second mechanical elements.

In a non-limiting example, and in another embodiment, a plurality ofpeaks can be formed into the upper surface of the container bodyperipheral wall, which can mate with a plurality of valleys formed intothe undersurface of the lidding body. In an alternate embodiment, aplurality of peaks can be formed into the undersurface of the liddingbody, which can mate with a plurality of valleys formed into the uppersurface of the container body peripheral wall. In either arrangement,the peaks on the lidding body can be formed to have complementarystructures relative to spaces between peaks on the container body, suchthat when lidding body properly aligned and placed atop the containerbody, the number and overall surface area of the contact surfacesbetween the container body and the lidding body can be increased. Anadhesive material can be applied to one or more of these additionalsurfaces to provide a more secure fit between the container body andlidding body.

As shown in FIG. 30 , an undersurface 161 of lidding body 152 caninclude a plurality of lid peaks 165 separated by lid valleys 166, whichcan mate with a correspondingly-shaped plurality of container peaks 175and container valleys 176, respectively, having a complementarily-shapedstructure, and formed into the upper surface 156 of the peripheral wall154 of container body 151. Securing lidding body 152 and container body151 forms dosage form 150, illustrated in FIG. 31 . In variousembodiments, each of the peaks 165,175 can have an identical sizerelative to each other, though in alternative embodiments, one or moreof the peaks 165,175 can be larger, smaller, or have different shapesrelative to other peaks 165,175, so long as there are a correspondingnumber of valleys 176,166 on the container body and lidding body,respectively, with complementary size(s) and shape(s) to receive them.Without being limited by a particular theory, providing a repeatingseries of uniformly sized and/or shaped peaks 165,175 and valleys166,176 can provide a precise fit that ensures that the lidding body 152is placed onto the container body 151 properly in any orientation of thelidding body 152 with the container body 151 each time a dosage form 150is assembled. In another embodiment, an adhesive material can be appliedto one or more of the peaks and/or valleys, in in addition to any one ormore of the contact surfaces described above.

In another embodiment, the lidding body can also be formed in the shapeof a container, configured to be inverted and placed over a containerbody 101, creating a dosage form 200 in which the lidding body envelopsthe upper surface 106 of the container body 101 and extends along atleast a portion of the external surface 105 of the peripheral wall 104.As shown in FIG. 32 , the lidding body 202 has a perimeter wall 207 thatextends from the peripheral portion 212 of the lidding body undersurface211, and having a bottom edge surface 215 and an inner surface 216. Theinner surface 216 is formed to define a diameter d₄ of the lidding bodyundersurface 211 that can be identical to, or only very slightly smallerthan, the diameter, d₂, of the container base 103, to allow the innersurface 216 of the perimeter wall 207 to frictionally engage with theexternal surface 105 of the peripheral wall 104. In an embodiment, theperimeter wall 207 can be configured so its inner surface 216 can engagewith the entire external surface 105 of the peripheral wall 104, andform a planar bottom surface 217 of the dosage form 200 with thecontainer base 103, shown in FIG. 33 . In an alternate embodiment, thediameter d₄ of the lidding body undersurface 211 can be configured to beslightly larger than the diameter d₂ of the container base 103, butsmall enough for the inner surface 216 of the peripheral wall 207 toadhere to the external surface 105 of the peripheral wall 104 upon theapplication of an adhesive material to either the inner surface of 216the perimeter wall 207, the external surface 105 of the peripheral wall104, or both.

FIG. 34 shows an embodiment of a lidding body 252 having a trio of pins258 extending from an undersurface 255 of the lidding body 252, toengage a corresponding trio of slots 259 in the peripheral wall 254 ofthe container body 251. The lidding body 252 also includes an internalprojection 257 that extends partially into the cavity 256 of thecontainer body 251. The pins 258 engagement with the slots 259 preventboth angular rotation and lateral movement of the lidding body 252relative to the container body 251. The fitment of the side edges of thepins 258 with the inner surfaces of the slots 259 maintains the liddingbody 252 engaged with the container body 251 during subsequent handling,packaging and use of the article.

FIG. 35 shows another embodiment of a lidding body 272 having a pair ofrectangularly-shaped pins 278 extending from opposite sides of an outersurface of the peripheral edge 277 of the lidding body 272, to engagewith and fit down within a pair of congruently-shaped slots 279 formedinto opposite sides of the upper surface 276 of the peripheral wall 274of the container body 251. The pins 278 engagement with the slots 279,as shown in FIG. 36 , prevent angular rotation and inward axial movementof the lidding body 272 relative to the container body 271, while theouter surface of the peripheral edge 277 of the lidding body 272 inengagement with the inner surface of the peripheral wall 275 of thecontainer body prevents lateral movement of the lidding body 272relative to the container body 271. The fitment of the side edges of thepins 278 with the inner surfaces of the slots 279 maintains the liddingbody 272 engaged with the container body 271 during subsequent handling,packaging and use of the article.

FIG. 37 shows an embodiment of a lidding body 282 having a pair ofdiametrically-opposed keystone-shaped slots 289 in the extendingperipheral wall 284, and a container body 281 having a pair ofdiametrically-opposed keystone-shaped pins 288 extending from the uppersurface 287 of the peripheral wall 284 of the container body 281. Thepins 288 are of a congruent shape and dimension of the slots 289, thoughtypically slightly shorter lengths and dimensions to allow the pair ofpins 288 to slide laterally into the pair of slots 289. FIG. 38 showsthe lidding body 282 being assembled to the container body 281 by firstaligning the lidding body 282 axially offset from the container body281, so that the pins 288 align laterally from the slots 289, and thenengaging the keystone pins 288 in the container body 281 into thekeystone slots 289 in the lidding body 282. Subsequently, the liddingbody 282 is moved laterally so that the two pins 288 simultaneouslyslide into the corresponding slots 289. In this embodiment, the engagedlidding body 282 is prevented from moving relative to the container body281 in the axial direction, rotatively, and in any other lateraldirection than the sliding direction. The fitment of the inside surfacesof the keystone-shaped slots 289 with the outside surfaces of thekeystone-shaped pins 288 maintains the lidding body 282 engaged with thecontainer body 281 during subsequent handling, packaging and use of thearticle.

FIG. 39 shows an embodiment of a lidding body 292 having a pair ofpartially tapered threads 298 extending outwardly from a projectionportion 294 of the undersurface 293 of the lidding body 292. The leadedge 299 of each thread 298 is configured to engage with a tapered slot290 within the inner wall 295 of the container body 291. The lead edge299 of each thread 298 can be aligned with a respective slot 290 andthen rotated in a clockwise direction, c, as the undersurface 293 of thelidding body 292 is lowered onto the upper surface 297 of the containerbody 291. The fitment of the outer surfaces of the thread 298 with theinner surfaces of the slot 290 maintains the lidding body 292 engagedwith the container body 291 during subsequent handling, packaging anduse of the article.

In another embodiment, any of the rapidly-orodispersible structuresabove can be formed in any 3DP equipment assembly with an open printbed. One such non-limiting example of a 3DP equipment assembly isdescribed in U.S. Pat. No. 8,888,480, the disclosure of which isincorporated by reference in its entirety.

FIG. 40 shows a partial cross-sectional view of a build module 300comprising a body 301 having an inner wall 301 b and an upper surface301 a and a height adjustable platform 302 having an upper surface 302a. A removable build plate 306 is placed on top of the platform 302.Process steps to form a rapidly-orodispersible dosage form areillustrated in a series of steps, labeled as steps A, B, C and D below,at various platform height-adjusted stages. The build module 300 andupper surface 306 a of the removable build plate 306 is depicted instarting position at an initial platform stage 0.

In step A1 shown in FIG. 41 , the upper surface 306 a of the removablebuild plate 306 is lowered (small arrow down) within the inner wall 301b of the build module 300, forming a cavity 303 bounded by the innerwall 301 b and the upper surface 306 a of the removable build plate 306.It should be understood that the segment illustration shown in step A1extends across the entire build module.

In process step B1, a substantially uniform layer of powder 124 isdeposited within the cavity 303 and its upper surface 125 made levelwith (at the same height of) the position of the upper surface 301 a ofthe build module. Typically, the powder layer 124 is formed bydepositing a volume of the powder material into the cavity 303 more thansufficient fill the entire volume of the cavity 303, and the uppersurface leveled using a leveling blade or roller. It should beunderstood that the segment illustration shown in step B1 extends acrossthe entire build module.

In process step C1, a printing liquid is deposited, in a predeterminedpattern and in predetermined amounts, by a printing apparatus 27expressing streams of droplets 21 from nozzles 23 onto the top surface125 of the powder layer 124. In the illustrated process, a plurality ofpatterns of streams of droplets 21 a are expressed, each pattern areabeing circular. The expressed printing liquid in the printed patternsforms a layer of printed powder 134 including the predetermined patternof printed powder material and non-printed powder material. It should beunderstood that the segment illustration shown in step C1 extends acrossthe entire build module.

After completing the liquid printing, the first layer of printed powdermaterial 134 is formed into a first layer of bound powder 144,comprising predetermined patterned areas of bound powder and remainingareas of unbound (non-printed) powder material, shown in step D1. Eachof the patterned areas of bound powder corresponds to an area andthickness of a circular base for a dosage form, such as circular base 3shown in FIG. 1 . It should be understood that the segment illustrationshown in step D1 extends across the entire build module.

In some embodiments, the process of Steps A1, B1, C1 and D1 can berepeated in series, one or more additional times, to deposit a secondlayer of powder material, to deposit binding liquid in the printedpatterns in registry with the printed powder material areas of the firstlayer of printed powder 134, and to form a plurality of thicker, two-(or more-) layered circular base for a container body.

In step A2 shown in FIG. 42 , the upper surface 306A of the removablebuild plate 306 is again lowered by an increment distance within thebuild module 300, re-forming a cavity 303 above the upper surface of thefirst layer(s) of bound powder 144.

In process step B2, another substantially uniform layer of powder 124 isdeposited within the cavity 303 above the upper surface of the firstlayer(s) of bound powder 144, and its upper surface 125 made level with(at the same height of) the position of the upper surface 301 a of thebuild module.

In process step C2, a printing liquid is deposited, in a secondpredetermined pattern and in predetermined amounts, by the printingapparatus 27 expressing streams of droplets 21 from nozzles onto the topsurface of the second powder layer 224. In the illustrated process, aplurality of patterns of streams of droplets 21 b are expressed, eachpattern area being annular. The expressed printing liquid in the printedpatterns forms a second layer of printed powder 234 including thepredetermined pattern of printed powder material in the form of an outerring with unwetted, unbound powder in a central area within the wettedouter ring.

After completing the liquid printing, the second layer of printed powdermaterial 234 is formed into a second layer of bound powder 244,comprising predetermined patterned areas of bound powder and remainingareas of unbound (non-printed) powder material, shown in step D2. Eachof the patterned areas of bound powder corresponds to an area andthickness of an annular wall for the dosage, such as annular wall 6shown in FIG. 1 , with unbound powder material within and betweenadjacent annular wall portions 104.

In some embodiments, the process of Steps A2, B2, C2 and D2 can berepeated in series, one or more additional times, to deposit anadditional layer of powder material, to deposit binding liquid in theprinted patterns in registry with the printed powder material areas ofthe first layer of printed powder 234, and to form a plurality ofthicker, two- (or more-) layered annular walls for the container body.FIG. 43 illustrates the steps A3, B3, C3, and D3 for forming of a thirdlayer of bound powder 344 on top of the second layer of bound powder244, forming a second layer of annular wall 104.

The completion of the printing of the annular walls 104 completes acontainer body 101 as illustrated in FIG. 28 . In some embodiments, theprinting process can be stopped and the printed container bodies 101removed from the build module 300 and the removable build plate 306, andseparated from any unbound powder material.

In step A4 shown in FIG. 44 , a cavity mask sheet 310 is placed over theupper surface of the third layer(s) of bound powder 344, above the buildmodule 300, and a vacuum hood 320 placed over the cavity mask sheet 310.The cavity mask sheet 310 includes a sheet or plate of a resilientmaterial that extending across the open area of the build module. Thecavity mask sheet 310 includes shaped openings 311 that are positionedin the cavity mask sheet 310 to register with each of cavities 34 of theplurality of container parts. Preferably, the cavity mask sheet 310 hasan undersurface that is placed into a contact with the upper edges ofthe printed container parts, and the shaped openings 311 position toavoid fluidizing and evacuating unbound powder material that remainspositioned between the outer surfaces of the formed container parts, toprevent or inhibit shifting or lateral movement of the formed containerparts in subsequent process steps.

In step B4 shown in FIG. 44 , the vacuum is applied and the drawn airfluidizes the unbound powder within the cavities of the printedcontainer parts, without displacing or moving the printed, bound-powdercontainer parts or the unbound powder between the container parts.

In step C4, the vacuum is halted and the vacuum hood 320 withdrawn fromabove the cavity mask sheet 310.

In step D4, a particulate payload material 60 comprising one or moremedicaments is deposited in a pre-determined amount into each cavity 34.A pre-determined amount, by mass or volume, of the particulate payloadmaterial 60 can be mechanically dosed and/or metered into the cavities34 by any means known in the art, non-limiting examples of which aredescribed in U.S. Pat. Nos. 9,409,699 and 9,828,119, and US PatentPublications 2017/0322068 and 2018/0031410, the disclosures of which areincorporated by reference in their entireties.

In step A5 shown in FIG. 45 , the upper surface 306 a of the removablebuild plate 306 is again lowered by an increment distance within thebuild module 300, re-forming a cavity 303 above the upper surface of thethird layer(s) of bound powder 344 with the cavities filled withparticulate payload material 60.

In process step B5, another substantially uniform layer of powder 424 isdeposited within the cavity 303 above the upper surface of the thirdlayer(s) of bound powder 344, and its upper surface made level with (atthe same height of) the position of the upper surface 301 a of the buildmodule.

In process step C5, a printing liquid is deposited, in a fourthpre-determined pattern and in pre-determined amounts, by the printingapparatus 27 expressing streams of droplets 21 from nozzles onto the topsurface of the fourth powder layer 424. In the illustrated process, aplurality of patterns of streams of droplets 21 are expressed, eachpattern area being circular. The expressed printing liquid in theprinted patterns forms a layer of printed powder 425 including thepre-determined pattern of printed powder material and non-printed powdermaterial.

After completing the liquid printing, the fourth layer of printed powdermaterial 425 is formed into a fourth layer comprising predeterminedpatterned areas of bound powder 444 and remaining areas of unbound(non-printed) powder material, shown in step D5. Each of the patternedareas of bound powder 444 corresponds to an area and thickness of acircular top for a dosage form 1, such as circular top 5 shown in FIG. 1.

FIG. 46 shows an alternative process for extracting unbound powder fromwithin the cavities 34 of the formed container bodies 101, as an optionto the process described above for FIG. 44 . Step A4′ shows a vacuumhood 320 in placed over the upper surface of the third layer(s) of boundpowder 344, above the build module 300. The vacuum hood 320 has an inletopen area 321 of substantially the upper open area of the build module300. The vacuum hood 320 includes a coarse screen 322 extending acrossthe inlet open area 321, the openings in the coarse screen 322 beingsufficiently large to allow fluidized unbound powder material to bedrawn into the vacuum hood 320 and into a powder recovery system, thoughnot so large that printed container bodies 101 are not pulled into thevacuum system or moved from their positions. Preferably, the coarsescreen 322 has an undersurface 323 that is placed into a contact withthe upper edges of the printed container parts to prevent their movementupon the build plate 306.

In step B4′ shown in FIG. 46 , the vacuum is applied and the drawn airfluidizes the unbound powder within and surrounding the printedcontainer bodies 101, substantially without displacing the printed,bound-powder container bodies 101.

In step C4′ shown in FIG. 46 , the vacuum is halted and the vacuum hood320 withdrawn from above the build module 300. Each container body 101is shown having a lower base 103 with an annular wall 104 surrounding acavity 34.

In step D4′ shown in FIG. 46 , particulate payload material 60comprising one or more medicaments is deposited in a pre-determinedamount into each cavity 34. A pre-determined amount, by mass or volume,of the particulate payload material can be mechanically dosed and/ormetered into the cavities 34 by any means known in the art, non-limitingexamples of which are described in U.S. Pat. Nos. 9,409,699 and9,828,119, and US Patent Publications 2017/0322068 and 2018/0031410, thedisclosures of which are incorporated by reference in their entireties.

FIG. 47 shows an alternative process for forming a plurality ofcontainer bodies in a series of steps, using the bound-powder printingprocesses described above, where in the container bodies are formedbottom sides up. The process in step A6 shows the completed steps afterforming a powder layer and printing a binding liquid on selectedportions of the powder layer to form a plurality of the upper peripheralwall portions 104 a consisting of the bound powder matrix, illustratingthat the top side of the container bodies (the upper portion of theperipheral walls) being formed down, while the process in step B6 showsthe completed steps after forming a powder layer and printing a bindingliquid on selected portions of powder layer to form the remainder of theperipheral walls 104 consisting of the bound powder matrix. The processin step C6 shows the completed steps after forming a powder layer andprinting a binding liquid on selected portions of the powder layer toform a plurality of bases consisting of the bound powder matrix, uponthe peripheral wall portions, to form the plurality of dosage containerbodies with the bottom sides (bases) facing up. After forming thecontainer bodies, the printed layers can be further processed toseparate the container bodies from the unbound powder material, whichcan be recovered and optionally recycled. The separated container bodiescan be optionally dedusted, and transported for further treatment andprocessing into dosage forms, or optionally packaged as separatearticles.

In an embodiment of the invention, which can be used with any otherembodiment described herein, the rapidly-orodispersible dosage forms canbe printed as an array of objects on top of the same build surface. Atop view showing a sample distribution of an array of printedrapidly-orodispersible containers 101 on a build plate 306 is shown inFIG. 48 . However, those skilled in the art would appreciate that anynumber of objects can be built on the same build surface in any pattern,based on the size of the build platform and the capabilities of the 3DPequipment assembly, and that other such examples are omitted forclarity.

In another embodiment, a plurality of lidding bodies can also be formedin a 3DP equipment assembly with an open print bed, according to thesame or similar process as described and depicted above. In anotherembodiment, lidding bodies can be printed on a separate build surfacefrom the container bodies. In another embodiment, lidding bodies can beprinted simultaneously on the same build surface as the containerbodies.

Unitary, Partially-Enclosed Dosage Form

FIGS. 49-54 illustrate forming, filling and sealing a unitary,partially-enclosed dosage form having an internal cavity, formed in anopen print bed of a 3DP equipment assembly. FIG. 49 shows a sectionalview of a container body 501 formed from a plurality of incrementallayers of build powder material 520, the container body 501 having abase 503 and a peripheral wall 504, with a cavity 534 bounded by theperipheral wall 504 that is filled with the entrapped build powdermaterial 50. A plurality of the container bodies being processed in anopen print bed is shown in FIG. 43 at step D3.

In the present embodiment, as illustrated in FIG. 50 , a build plate 306of the open print bed is lowered an incremental distance, and asubstantially uniform, incremental layer 524 of build powder material isapplied over the formed container body 501 and build powder material 50,and an area (arrows) on the upper surface 525 of the build powder layer524 illustrates where a printing liquid will be directed to form a boundpowder matrix. The area (arrows) has a periphery that is coextensivewith the outer peripheral wall 504 of the container body 501, andincludes an interior area where the printing (binder) liquid will not beprinted, and consequently, the build powder material will not betransformed into a bound powder matrix.

FIG. 51 shows a sectional view of the formed unitary, partially-encloseddosage form 509, resulting from the printing of the printing liquid. Theformed unitary, partially-enclosed dosage form 509 has an internalcavity 534 filled with unbound powder material 50, and a top lid 506formed of the bound powder matrix by the selected printing of the buildpowder layer 524. The bound powder matrix of the top lid 506 is securedor unitarily formed with the upper edge of the peripheral wall 504. Thetop lid 506 has a port opening 508 formed from unwetted and unboundbuild powder of the build powder layer 524.

FIG. 52 shows the use of an evacuation system to remove the unboundpowder material from within the cavity through the port opening. Anevacuation system V evacuates or removes the unbound build powdermaterial 50 from within the cavity 534, through the port opening 508 inthe lid 506. In the illustrated embodiment, the evacuation system isillustrated as a vacuum system which draws air and the fluidizingunbound build powder material 50 from within the cavity 534. A distaltip of a tube 87 connected to the vacuum system V can be inserted intoport opening 508 in the lid 506 to assist in evacuating most or all ofthe unbound build powder material 50, to leave an empty or substantiallyempty cavity 534. The inlet opening in the tube 87 should be larger thanthe largest particle size of the particulate build powder material. Theinlet opening in the tube 87 can be manually inserted into the portopening, or can be mechanical inserted under automatic control.

After most or all of the unbound build powder material 50 is evacuatedfrom the cavity 534, a payload material 60 can be deposited into theevacuated cavity. FIG. 53 shows a means for partially or completelyfilling the empty cavity 534 through the port opening 508 in the lid506, with a payload material 60. The payload material can be depositedinto the cavity 534 by any well-known means, such as a pipette 88 asillustrated, or an injection needle, which can be inserted through theport opening 508 and into the cavity 534 to avoid spillage or loss ofthe payload material. The payload material can be any of the solid,particulate, liquid, semi-solid or engineered particles and materialsdescribed herein. In some embodiments, after the payload material 60 hasbeen deposited into the cavity, a filler material (not shown, butdescribed herein) that is typically inert with the payload material, canbe deposited to fill the remaining volume of the cavity 534. In someembodiments, only a small portion of the unbound build powder material50 can be withdrawn from the cavity 534, the small portion by volumebeing sufficient to provide space for a small amount or volume of apayload material 60.

The unbound build powder 50 contained with the cavity 586 of thepartially-enclosed dosage form 509 can be evacuated while the dosageform 509 remains in the open print bed, as illustrated in FIG. 52 , orcan be further processed remote from the open print bed to separate thepartially-enclosed dosage form 509 from the unbound powder material,which can be recovered and optionally recycled. The separatedpartially-enclosed dosage form 509 can be optionally dedusted, andtransported for further treatment and processing into dosage forms, oroptionally packaged as separate articles.

After the payload is deposited into the cavity 534 of thepartially-enclosed dosage form 509, the port opening 508 in the lid 85can be closed and sealed to prevent the payload 60 and any remainingunbound build powder material 50 from escaping the cavity, forming afinished unitary dosage article 550 containing a payload, and further, arapid-orodispersive unitary dosage article containing a payloadmaterial, such as a medicament, within the sealed, interior cavity. FIG.54 shows a plug 589 filling and sealing the port opening 508. Thesealing material of the plug 89 can be a solid or solidifying material,and preferable a water-soluble and ingestible material. A preferredmaterial is a solid or waxy material at normal room or storagetemperatures, and meltable at elevated temperatures to flow into andseal the edges of the port opening 86. Non-limiting examples of asealing material are fats, water-soluble polymers, polyethylene glycol,carbohydrates and carbohydrate alcohols, including any one or morethermal binding materials as described herein.

In another embodiment, rather than forming the port opening within theunitary lid, a port opening can be formed into a peripheral wall of thedosage form, and into fluid communication with the internal cavitywithin the container. An advantage of forming the port opening in theperipheral of a disk-shaped dosage form can be that the bound powdermatrix of the peripheral wall surrounding the port opening has betterstructural integrity than the lid portion or the base of the containerbody. The portion of the peripheral wall in which the port opening isformed can also be formed more thickly for better structural integrity.The top lid portion and base portions of dosage forms are stamped,embossed or printed with a logo or other mark for the dosage formproduct, and forming a port opening into a peripheral wall of the dosageform avoids marring of the logo or other mark.

FIG. 55 shows a formed unitary, partially-enclosed dosage form 509having a port opening 518 formed in a peripheral wall 504, into fluidcommunication with the internal cavity 534 within the container 501. Theport opening 518 is formed from unwetted and unbound build powder thatwas not wetted or printed during the printing of the peripheral wallsegments in previously-deposited build powder layers. A continuous toplid portion 506 can be printed onto the upper-most build powder layer525, thereby forming the unitary, partially-enclosed dosage form 509with the unwetted port opening 518.

The build powder 50 contained within the cavity 534 can be removed orevacuated as described above, for example, by a vacuum system. As shownin FIG. 56 , a payload material 60 can be deposited into the evacuatedcavity 534 through the port opening 518 in the peripheral wall 504, byany well-known means, as described above. After the payload is depositedinto the cavity 534 of the partially-enclosed dosage form 509, the portopening 518 in the peripheral wall 504 can be closed and sealed toprevent the payload 60 and any remaining unbound build powder material50 from escaping the cavity, as described above and illustrated in FIG.52 .

In another embodiment, a port or opening for removing unbound powdermaterial from a filled or partially-filled cavity can be formed afterthe printing of a unitary dosage form is completed, as illustrated inFIGS. 57-60 . Similar to FIG. 50 , FIG. 57 illustrates a sectional viewof a container body 501 atop of an open print bed 306, the containerbody 501 formed from a plurality of incremental layers of build powdermaterial 520, the container body 501 having a base 503 and a peripheralwall 504, with a cavity 534 bounded by the peripheral wall 504 that isfilled with the entrapped build powder material 50. A substantiallyuniform, incremental layer 524 of build powder material is applied overthe formed container body 501 and build powder material 50, and an area(arrows) on the upper surface 525 of the build powder layer 524illustrates where a printing liquid will be directed to form a boundpowder matrix. In contrast to the application of printing liquid asillustrated in FIG. 50 , although the area (arrows) has a periphery thatis coextensive with the outer peripheral wall 504 of the container body501, the entire incremental layer 524 is contacted with the printing(binder) liquid, therefore transforming the entire incremental layer 524into a bound powder matrix, and forming a lid portion 506 unitary withthe container body 501, as shown in FIG. 58 . The formed unitary,fully-enclosed dosage form 519 has an internal cavity 534 filled withunbound powder material 50. The bound powder matrix of the top lid 506is secured or unitarily formed with the upper edge of the peripheralwall 504.

FIG. 59 shows a sectional view of the use of a boring means 55,illustrated in FIG. 59 as a drill bit to create a port opening 528 inthe peripheral wall 504 of the unitary, fully-enclosed dosage form 519.Once the port opening 528 is created, an evacuation system, V, can alsobe used to evacuate or remove the unbound build powder material 50 fromwithin the cavity 534, through the port opening 508 in the peripheralwall 504. In the illustrated embodiment, the evacuation system V isillustrated as a vacuum system which draws air and either a portion ofthe bound matrix when forming the port opening 528, or unbound buildpowder material 50 from within the cavity 534. As illustrated in FIG. 52, a distal tip of a tube 87 connected to the evacuation system V can beinserted into port opening 508 in the lid 506 to assist in evacuatingmost or all of the unbound build powder material 50, to leave an emptyor substantially empty cavity 534.

After most or all of the unbound build powder material 50 is evacuatedfrom the cavity 534, a payload material 60 can be deposited into theevacuated cavity. FIG. 60 shows a means for partially or completelyfilling the empty cavity 534 through the port opening 528 in theperipheral wall 504, with a payload material 60. The payload materialcan be any of the solid, particulate, liquid, semi-solid or engineeredparticles and materials described herein, and can be deposited throughthe port opening 528 and into the cavity 534 by any well-known means, asdescribed above. In some embodiments, after the payload material 60 hasbeen deposited into the cavity, a filler material (not shown, butdescribed herein) that is typically inert with the payload material, canbe deposited to fill the remaining volume of the cavity 534. In someembodiments, only a small portion of the unbound build powder material50 can be withdrawn from the cavity 534, the small portion by volumebeing sufficient to provide space for a small amount or volume of apayload material 60.

One or both of the formation of the port opening 528 and the evacuationof unbound build powder 50 contained with the cavity 534 of thefully-enclosed dosage form 519 can occur while the dosage form 519 isstill on the open print bed (not shown). Alternatively, fully-encloseddosage forms 519 can be further processed remotely from the open printbed to form the port opening 528 and/or separate the fully-encloseddosage form 519 from the unbound powder material, which can be recoveredand optionally recycled.

After the payload 60 is deposited into the cavity 534 of the dosage form519, the port opening 528 in the peripheral wall 504 can be closed andsealed to prevent the payload 60 and any remaining unbound build powdermaterial 50 from escaping the cavity, forming a finished unitary dosagearticle 560 containing a payload 60, and further, a rapid-orodispersiveunitary dosage article containing a payload material, such as amedicament, within the sealed, interior cavity 50. FIG. 60 shows a plug589 filling and sealing the port opening 528. Any of the sealingmaterials described above can be utilized to form the plug and seal theedges of the port opening 528.

In another embodiment, rather than forming the port opening 528 withinthe peripheral wall 504, a port opening can instead be formed into theunitary lid 506 of the dosage form 519, and into fluid communicationwith the internal cavity 534 within the container 501 (not shown).

Printing Liquid

In another embodiment, the spacing of droplets of printing liquiddispensed by a 3DP equipment assembly, including any of the systemsdescribed above, can be described in terms of the resolution of theprinting system, often expressed as dots per inch (dpi), which is thereciprocal of droplet spacing. For example, resolutions of 300 and 600dpi correspond to droplet spacings of about 84.7 microns and about 42.3microns, respectively. The drop-to-drop spacing (within a line), or theline spacing (spacing of droplets from one line to the next), or anyother spacing of droplets may be described in terms of resolutionexpressed in dpi. In some embodiments, layer-by-layer instructions formaking the dosage forms may consist of a series of pixelated imagescharacterized by a resolution in dpi in each of two orthogonal lineardirections. In some instances, these pixelated images are 1-bitmonochrome images, alternately referred to as binary or bi-level imagesin which each pixel contains one bit of information (0 or 1) that may berepresented as either black or white onscreen.

In other embodiments, layer-by-layer instructions for making the dosageforms may consist of a series of voxels, or unit volumes, defined by onedrop-to-drop spacing in the fast axis direction of motion, by oneline-to-line spacing in the slow axis direction of motion, and by onelayer thickness in the vertical direction. Some of the unit volume canbe occupied by powder particles, while the remainder of the unit volumecan be empty space, referred to as the void volume. As used herein, theterms, “saturation level,” or “print density,” describes how much of thevoid volume is occupied by liquid dispensed as a drop or fluid unitwithin that particular voxel. The saturation level can also describe theratio of the dispensed fluid volume to the volume of empty space in thevoxel. In general, saturation levels may be chosen to be slightly lessthan, or somewhere approximately equal to, 1.0 (also expressed as 100%saturation). In some embodiments, the saturation level of printing stepsin any of the 3DP-based methods described herein during can range fromabout 10% to about 110%, about 15% to about 80%, about 20% to about 50%or about 15% to about 35%, either in aggregate across the dosage form,or otherwise in selected regions of the dosage form.

In some instances, the relative amount of binding in localized regionsof the dosage form is achieved by “grayscaling” (i.e., use of agrayscale print pattern) in the dosage form design. In the case of 1-bitmonochrome images used for machine instructions, grayscaling is achievedby changing the number of “black” pixels relative to “white” pixels in achosen region of a dosage form, or in a chosen layer of a dosage form,or throughout a dosage form. Any other regions that may be “solid” byusing all black pixels. In some embodiments, the dosage form designincludes a “solid” exterior and a “grayscaled” interior. In someembodiments, grayscaling may be achieved with equally spaced blackpixels amongst white pixels to reach an overall ratio of black to whitepixels in the grayscaled region. In other embodiments, grayscaling maybe achieved with randomly placed black pixels amongst white pixels toachieve an overall ratio of black to white pixels in the grayscaledregion. In still other embodiments, grayscaling may be achieved with achosen pattern (e.g., parallel lines, hashed pattern, dot pattern) ofblack pixels amongst white pixels to achieve an overall ratio of blackto white pixels in the grayscaled region.

In various embodiments, the printing system may apply droplets atdifferent respective droplet spacing for each of two orthogonal lineardirections. The dpi for each direction may vary based on the 3DP systemused, and in some instances may vary based on such factors as the totalcount and native spacings of nozzles on the printhead, the axis andvelocity of relative motion between printhead and substrate (i.e.,articles being formed), and the timing frequency with which each nozzlecan eject a unique droplet. These and related factors are recognized andare well known in the art. In one non-limiting example, a first dropletspacing is selected from 200 dpi to 500 dpi with respect to a firstorthogonal linear direction, and a second droplet spacing is selectedfrom 700 dpi to 1800 dpi with respect to a second orthogonal lineardirection.

Suitable printing devices can include those having a continuous jetprinthead or those having a drop-on-demand printhead. A continuous jetprinthead provides a continuous jet, or spray, of droplets whiledepositing printing fluid onto a powder layer. A drop-on-demandprinthead only deposits droplets of printing fluid onto the powder layerif it receives an instruction, demand, or operational command to do so.A printhead may scan, or apply fluid to, the surface of powder layerfrom left to right, or from fright to left, at a predetermined rate,e.g., a scan rate, to form a line of droplets.

Without being limited by a particular theory, it is believed that a highscan rate will result in a lower saturation level, and a low scan ratewill result in a higher saturation level when comparing printing fluiddeposition at a constant volume per unit time. When binder material ispresent in the binding solution, it is believed that a doubling of theprint speed, for example from 1.0 m/s to 2.0 m/s, can reduce the totalvolume of binder solution deposited in the tablets by approximately half(assuming constant dispensing rate from the nozzle). In contrast, it isbelieved that as the print speed increases, the bulk density of thetablet decreases. A simultaneous decrease in the dimensions and weightof the tablets may also be seen, and may be attributed to the fact thata decrease in the total volume of binder droplets deposited onto thepowder can result in a decrease in the extent of binder solutionspreading in the powder. Additionally, it is believed that increasingthe print speed can also decrease the flash time and hardness, as wellas increase the friability of the tablets, as a result of decreasing theproportion of decreases in the tablets as the print speed increases. Itis also believed that an increase in the print speed can also increasethe void volume inside the tablets

When using a continuous jet print head, the print head may scan at arate of about 0.5 m/sec to 3.0 m/sec. When a drop-on-demand jet printhead is used, the print head may scan at a rate of 0.1 m/sec to 1 m/sec,or from about 0.15 m/sec to about 0.5 m/sec.

Generally, the size or volume of individual droplets can be varied asdesired, for example, by selection of a different 3DP equipmentassembly, or different printhead components on the same machine, ordifferent parameters on the same printhead and same machine. Withoutbeing limited by a particular theory, it is believed that increasing thesize or volume of the droplet can increase the saturation level, whiledecreasing the size or volume of a droplet can reduce the saturationlevel when the printing fluid is deposited at a constant scan rate. Inanother embodiment, when using a continuous jet printhead, the size ofthe fluid droplets delivered by the printhead can be in a range fromabout 15 microns to about 150 microns in diameter. In anotherembodiment, when using a drop-on-demand printhead, the size of the fluiddroplets delivered by the printhead can be in a range from about 50microns to about 500 microns in diameter.

The flow rate of the fluid delivered by the printhead can also be variedas desired. Without being limited by a particular theory, it is believedthat increasing the flow rate can increase the saturation level, anddecreasing the flow rate can reduce the saturation level when theprinting fluid is deposited at a constant scan rate. Generally, theprinthead can deposit droplets of printing fluid to form parallel linesthereof in the powder layer. In another embodiment, when using acontinuous jet printhead, the line spacing can be in a range from about20 microns to about 1000 microns, from about 50 to about 500 microns, orfrom about 100 to about 200 microns. In another embodiment, when using adrop-on-demand jet printhead, the line spacing can be in a range fromabout 20 microns to about 300 microns, from about 40 microns to about100 microns, or from about 55 microns to 75 microns.

In another embodiment, the mass of moisture within a dosage form can bequantified as a percent by mass that is lost as a result of drying(LOD). In another embodiment, the dosage form can comprise not more than10% by weight, not more than 7.5% by weight, not more than 5% by weight,not more than 4% by weight, not more than 3% by weight, not more than2.5% by weight, not more than 2% by weight, or not more than 1.5% byweight of moisture, as determined by LOD at 120° C. In anotherembodiment, the dosage form can comprise at least 0.1% by weight, atleast 0.2% by weight, at least 0.5% by weight, at least 0.75% by weight,at least 1% by weight, at least 1.5% by weight, at least 2% by weight,at least 2.5% by weight, at least 3% by weight, at least 4% by weight,or at least 5% by weight of moisture as determined by LOD at 120° C. Inanother embodiment, the dosage form comprises moisture in any rangebetween and inclusive of 0.1% by weight and 10% by weight, including butnot limited to: from at least about 0.1% by weight, up to about 10% byweight; or at least about 0.2% by weight, up to about 7.5% by weight; orat least about 0.5% by weight, up to about 5% by weight; or at leastabout 0.5% by weight, up to about 4% by weight; or at least about 1% byweight, up to about 3% by weight.

Powder Bed Selective Thermal Bonding

In an embodiment of the invention, a powder bed selective thermalbonding process and apparatus can be used to form a thermofused dosageform from a thermofusable powder material using a heat energy source.

In another embodiment, the thermofused dosage form can be formed withina depression of a dosage form package, such as a blister package.

FIG. 61 illustrates on the left side, L, a first layer 620 of athermofusable powder material 650 of a substantially-uniform thickness,t, formed within the base 12 of a depression 10 of a dosage formpackage, and on the right side, R, the emissions a matrix oflight-emitting elements 623 of a heat-emitting source 622 are controlledto direct the heat energy 621 across the entire surface of the firstpowder layer 620 for increasing the temperature of the thermofusablepowder material, which upon cooling forms a stabilized granularagglomerate of a thermofused first layer 624.

FIG. 62 illustrates on the left side, L, a subsequent or second layer625 of the thermofusable powder material 650 formed onto the stabilizedgranular agglomerate 624 of the thermofused first layer, and on theright side, R, the heat-emitting source 622 targets the heat energy 621at the thermofusable powder material in a selected peripheral portion625 c of the thermofusable powder material 650 of the second layer 625,thermally bonding the thermofusable powder material within the selectedperipheral portion 625 c into a stabilized granular agglomerate, whichalso bonds or attaches to the thermofused first layer 624 therebelow,while limiting or avoiding the application of the heat energy upon theremaining central portion 625 d of the second layer 625 of thermofusablepowder material that remains unbonded and un-agglomerated.

FIG. 63 illustrates on the left side, L, a subsequent or third layer 626of the thermofusable powder material 650 formed onto the selectivelythermofused second layer 625, and on the right side, R, theheat-emitting source 622 targets the heat energy 621 at thethermofusable powder material 650 in a selected peripheral portion 626 cof the third layer 626, again thermally bonding the thermofusable powdermaterial within the selected peripheral portion 626 c into a stabilizedgranular agglomerate, which also bonds or attaches to the stabilizedgranular agglomerate of the peripheral portion 625 c of the second layer625 below, while limiting or avoiding the application of the heat energyupon the remaining central portion 626 d of the third layer 626 thatremains unbonded and un-agglomerated.

FIG. 64 illustrates a partially thermofused article with five completedlayers, with the fourth 627 and fifth 628 layers formed substantially asthe third layer 626, where on the left side, L, a subsequent or sixthlayer 629 of the thermofusable powder material 650 is formed onto theselectively thermofused fifth layer 628, and on the right side, R, theheat-emitting source 622 targets the heat energy 621 at thethermofusable powder material 650 in a selected peripheral portion 629 cof the sixth 629 layer, again thermally bonding the thermofusable powdermaterial within the selected peripheral portion 629 c into a stabilizedgranular agglomerate, which also bonds or attaches to the stabilizedgranular agglomerate of the peripheral portion 628 c of the fifth layer628, while limiting or avoiding the application of the heat energy uponthe remaining central portion 629 d of the sixth layer 629 that remainsunbonded and un-agglomerated.

FIG. 65 illustrates on the left side, L, the partially-formed containerof FIG. 64 , with a vacuum system 35 withdrawing the unboundthermofusable powder 650 out of the central portion, to leave an emptycavity 634, and on the right side, R, a complete filling of the emptycavity 634 with a particulate (payload) medicament 660 to an uppersurface 661.

FIG. 66 illustrates on the left side, L, a top or last layer 670 of thethermofusable powder material 650 is formed onto and above the uppersurface of the peripheral thermofused portion 629 c of the sixth layer(629) and the upper surface 661 of the central portion-fillingmedicament 660, and on the right side, R, the heat-emitting source 622directs the heat energy 621 across the entire surface 662 of the toplayer 670 of thermofusable powder material 650, which upon cooling formsa stabilized granular agglomerate of a thermofused top layer 672,enclosing the medicament 660 within the walled cavity 634 of thestabilized granular agglomerate of the resulting dosage form 680.

The thermal binder is a material a glass transition temperature in therange of about 20 to about 160° C., preferably about 40 to about 140°C., more preferably about 55 to about 100° C. The thermal binder can becrystalline or amorphous and has the capability, after melting, tore-solidify upon cooling to below its glass transition temperature.Examples of suitable thermal binders include fats such as cocoa butter,hydrogenated vegetable oil such as palm kernel oil, cottonseed oil,sunflower oil, and soybean oil, mono, di, and triglycerides,phospholipids, waxes such as Carnauba wax, spermaceti wax, beeswax,candelilla wax, shellac wax, microcrystalline wax, and paraffin wax,water soluble polymers such as polyethylene glycol, polycaparactone,suitable fatty acid esters including sucrose fatty acid esters, mono,di, and triglycerides, glyceryl behenate, glyceryl palmitostearate,glyceryl monostearate, glyceryl tristearate, glyceryl trilaurylate,glyceryl myristate, GlycoWax-932, lauroyl macrogol-32 glycerides, andstearoyl macrogol-32 glycerides, polyethylene oxides and derivatives,and sucrose esters. Preferably, the thermal binder is selected fromhydrogenated vegetable oil, polyethylene glycol, waxes, and mixturesthereof. In one embodiment more than one thermal binder is used andcontained in the thermofusable powder material.

A particularly preferred thermal binder is polyethylene glycol (PEG)having at least 95% by weight of the PEG particles less than 100 micronsas measured by conventional means such as light or laser scattering orsieve analysis and a molecular weight between 3350 and 8000 Daltons.

The amount of thermal binder present in the thermofusable powdermaterial mixture is proportional to the particle size of the thermalbinder used. Where up to 95% by weight of the thermal binder in thethermofusable powder material (and the thermofused bound matrix) has aparticle size of less than about 100 microns (as measured byconventional means such as light or laser scattering or sieve analysis),the thermofusable powder material can comprise a range of 10-20% byweight of thermal binder. Where more than 50% by weight of the thermalbinder in in the thermofusable powder material (and the thermofusedbound matrix) has a particle size between about 100 and about 400microns as measured by sieve analysis, the thermofusable powder materialcan comprise a range of 15-40% by weight of thermal binder. The lowerparticle size of a thermal binder powder contributes a higher surfacearea within the bound matrix, wherein the thermal binder contributes agreater binding effect when heated and then cooled.

Another component of the thermofusable powder material is at least onecarbohydrate or carbohydrate alcohol selected from the group consistingof dextrose, sucrose, erythritol, mannitol, sorbitol, maltitol, xylitol,lactose, isomalt, starch hydrolysates, which include dextrins,dextrates, and maltodextrins, and the like, and mixtures thereof. Thecarbohydrate material contributes to the dissolvability and mouthfeel ofthe resulting dosage form, and also by aiding in distributing the drythermal binder across a broader surface area. The carbohydrate may bepresent at level of about 5 percent to about 95 percent of the dosageform, e.g., about 20 percent to about 90 percent or about 40 percent toabout 80 percent of the dosage form.

As the particle size of the thermal binder is decreased, less heat (interms of time of heating and temperature) is needed to melt the outersurface of the thermal binder particles to fuse the agglomerate andachieve the same hardness. In one embodiment the particle size of the ofcarbohydrate or carbohydrate alcohol can influence the level of thermalbinder used, wherein a higher particle size of carbohydrate orcarbohydrate alcohol provides a lower surface area and subsequentlyrequires a lower level of thermal binder. In one embodiment, wherein thethermal binder comprises 10-20% by weight of the thermofusable powdermaterial when the carbohydrate or carbohydrate alcohol has a meanparticle size of the carbohydrate or carbohydrate alcohol is greaterthan 100 μm and is greater than 50% by weight of the thermofusablepowder material.

As described herein for a bound matrix that is formed by depositingand/or forming a layer of powder material and wetting with a bindingliquid, the layer of thermofusable powder material can optionally betamped or compressed after formation and prior to the heating or fusingstep, in order to reduce void space and remove air from thethermofusable powder mixture. In one embodiment the tamping step is notenough pressure or force to hold the tablet shape together. In oneembodiment the tamping step is conducted using a force less than 0.3kiloNewtons. In various embodiment, the bound matrix or granularagglomerate can be tamped as the bound matrix is cooling, and before ithas fully cooled and hardened.

Temperatures of the thermofusable powder material and the granularagglomerate formed therefrom can be measured using a thermocoupletemperature measuring sensor, such as a thermocouple Type K commerciallyavailable from the Hewitt Industries.

The thermofusable powder material in the formed layer can be heated to atemperature and for a period of time to softener and/or melt the thermalbinder partially or substantially throughout the powder layer. Themelted thermal binder begins to flow and forms a fused aggregateportion, fusing multiple particles together, and fusing the layer ofthermofusable powder material to a bound powder layer below. The otherparticulate components in the thermofusable powder can remain solid andmaintain their physical properties, including hardness. The time ofheating is dependent on the species of thermal binder and its particularsize dimensions, and particularly the thickness, of the layer ofthermofusable powder material, and must be sufficient in conjunctionwith the temperature to fuse and stabilize the particulate agglomerate.

A suitable heat source to heat selected portions in the plane of thelayer of thermofusable powder material should be directed at specificplanar surfaces of the layers, with high resolution, in order to avoidheating of portions of the powder layer which are intended not to beheated and agglomerated. A suitable heat source can be a radiant heater,conductive heating, convective heating, radiofrequency heating, sonicheating, microwave heating, or laser heating. In various embodiments,the heat source includes a means for selectively directing the heatenergy for increasing the temperature of the thermofusable powdermaterial only upon and into the planar portion of the layer of powderthat is to be thermally bonded, while limiting or preventing the heatenergy upon or into the remaining planar portions of the layer of powderthat is remain unbonded and un-agglomerated.

In one embodiment, said means can comprise a targeting heat source thattargets heat energy only at the areas of the thermofusable powder layerto be bonded. Non-limiting examples of such targeting heat energy caninclude a laser heat source.

In a preferred embodiment, the laser heat source emits electromagneticradiation at a wavelength, and can include one or more lasers. Types oflasers can include, for example, CO2 lasers, infrared lasers, and diodelasers such as blue diode lasers. The thermal binder material, causingthe thermal binder material to be heated and to soften and/or melt afterbeing heated to its glass transition or melt temperature. Theelectromagnetic radiation can be electromagnetic radiation within theinfrared, visible or ultraviolet regions of the electromagneticspectrum. The laser power can be measured in watts, and is at least 0.5W, including at least 1 W, at least 1.5 W, and at least 2 W, and up to140 W, including up to 80 W, up to 7 W, up to 5 W, and/or up to 3 W.

The laser emits electromagnetic radiation having a wavelength in therange of from 200 nanometers (nm) to 11 micrometers (μm), preferably 315nm to 1.4 μm, more preferably 380 nm to 800 nm, such as 400 nm to 610nm, preferably 400 nm to 500 nm, more preferably 430 nm to 470 nm. Othersuitable wavelength ranges can include 9.4 to 11 μm, such as 10.2-10.8μm, preferably around 10.6 μm. Another suitable laser emitselectromagnetic radiation in the range of 750-850 nm, such asapproximately 800 nm.

The targeted heating with the laser heat source is performed using ascan speed in the range of from 5 mm/s to 50,000 mm/s, preferably from10 mm/s to 1,000 mm/s, more preferably from 20 mm/s to 300 mm/s and mostpreferably from 30 mm/s to 200 mm/s.

The selective laser activation is performed using a surface temperaturein the range of 0-200° C., preferably 40-180° C., most preferably70-170° C.

The parameters that can be varied typically include the type of laserand thus its wavelength, as well as the laser power, scan speed, printresolution (layer height), beam spot size, surface temperature of thethermofusable powder material layer, the ambient or chamber temperature,and the initial position of the build platform and its lowering speed.

In various embodiments, a height of the layer of thermofusable powdermaterial is in the range of 0.001 mm to 15 mm, which can include atleast 0.025 mm, at least 0.05 mm, at least 0.1 mm, and at least 0.5 mm,and up to 10 mm, including up to 5 mm, up to 2 mm, and up to 1 mm.

Suitable laser beam spot size is typically in the range of from 0.0025mm to 1 mm, for example 0.05-0.5 mm, preferably 0.1-0.3 mm, for example0.2 mm. Increasing the spot size can be used to increase the laser beaminteraction time. Typically, this is influenced by adjusting the scanspeed.

In another embodiment, said means can comprise a heat source thatdirects heat energy at the areas to be bonded, while shielding thedelivery of the heat energy at or onto areas of the thermofusable powderlayer that are to remain unbonded and un-agglomerated. Non-limitingexamples of such directing heat energy can include a radiant source,convective heating, radiofrequency heating, sonic heating, or microwaveheating, while a shielding means can include an areal template that isapplied upon to cover the surface of the portion of the layer ofthermofusable powder that is to remain unbound, where the template is amaterial that can reflect away or absorb the heat energy, to prevent orgreatly restrict its penetration therethrough to the powder materialbeneath.

FIGS. 67 and 68 illustrate selected steps in a process for forming ofone or more porous articles, each having one or more internal cavitiesdisposed inside. A method can include the steps of depositing a layer ofthermofusable powder material, positioning a shield over the uppersurface of the powder layer, and directing heat energy through the oneor more openings in the shield to selectively bond the thermofusablepowder material into a stabilized granular agglomerate, while leavingthe portions of the thermofusable powder material that are shielded fromthe heat energy to remain unbonded and un-agglomerated.

FIG. 67 illustrates a module 700 similar to the build module 300 shownand described in FIG. 40 . In step A-1, the upper surface 706 a of theremovable build plate 706 is lowered (small arrow down) within the innerwall 701 b of the build module 700, forming a cavity 703 bounded by theinner wall 701 b and the upper surface 706 a of the removable buildplate 706. It should be understood that the segment illustration shownin step A1 extends across the entire build module.

In process step A-2 of FIG. 67 , a substantially uniform layer ofthermofusable powder 724 is deposited within the cavity 703 and itsupper surface 725 made level with (at the same height of) the positionof the upper surface 701 a of the build module. Typically, thethermofusable powder layer 724 is formed by depositing a volume of thethermofusable powder material into the cavity 703 more than sufficientto fill the entire volume of the cavity 703, and the upper surface isleveled using a leveling blade or roller. It should be understood thatthe segment illustration shown in step A-2 extends across the entirebuild module.

In process step A-3 of FIG. 67 , a shield 590 is positioned above theupper surface 725 of the thermofusable powder layer 724. The shield 590is typically a planar material 591 having openings formed through theplanar material, and is placed above and substantially parallel to theupper surface 725 of the thermofusable powder layer 724. In someembodiments, the heat source is a laser light source. The planarmaterial can be formed from one or more materials that can reflect awayor absorb the heat energy of the laser light, to prevent or greatlyrestrict penetration of the laser-light heat energy therethrough to thepowder material beneath. To form a uniform circular first or base layerof stabilized granular agglomerate, the openings 592 in the shield 590are open circles, the openings 592 spaced apart in a selected pattern inthe planar material 591, defined by rims 593 as shown in FIG. 69 . Theshield 590 can be placed directly above, or alternatively spaced asuitable distance above, the upper surface 725 of the thermofusablepowder layer 724. It should be understood that the segment illustrationshown in step A-3 extends across the entire build module.

After positioning of the shield 590, laser light 721 is emitted fromlight-emitting elements 723 of an energy source 722 as illustrated instep A-4 of FIG. 67 . The areal shape and pattern of the light-emittingelements 723 can be placed on the undersurface of the energy source 722in the same shape as the removable build plate 706 of the build module700, so that the entire surface of the removable build plate 706 anduniform thermofusable powder layer 724 are exposed to the emitted heatenergy simultaneously. In an alternative embodiment, a laser light heatsource can have a smaller area of light emission that can be maneuveredlaterally above the shield 590 to expose the removable build plate 706and uniform thermofusable powder layer 724 in a predetermined durationand pattern of heat energy. The laser light energy passing through theopenings 592 in the shield 590 strikes the exposed portions 726 of theupper surface 725 of the thermofusable powder layer 724, to heat thethermofusable powder material beneath the exposed surface 726, whichcauses the thermal binder material within the thermofusable powdermaterial to soften and/or melt sufficiently. The energy intensity andduration can be selected to provide sufficient softening and melting ofthe thermal binder material in the exposed surface portions 726, whileavoiding complete liquifying of the thermal binder material, while theshield 590 prevents or minimizes heating, and bonding or agglomeration,of the thermofusable powder material 724 in the shielded surfaceportions 727. It should be understood that the segment illustrationshown in step A-4 extends across the entire build module.

After the heat energy is stopped or removed, the shield 590 is removedfrom over the upper surface 725, revealing a selectively thermofusedfirst layer or base layer 775, as shown in step A-5 of FIG. 67 . As theexposed heated powder material cools, the thermofusable powder materialbeneath the exposed surface 726 has become bonded together intostabilized granular agglomerate, forming the thermofused base portions734 of the container article, while the thermofusable powder material inthe shielded portions 727 remains unbonded and free-flowing. Each of thepatterned areas of bound powder corresponds to an area and thickness ofa circular base for a dosage form, such as circular base 3 shown in FIG.1 . It should be understood that the segment illustration shown in stepA-5 extends across the entire build module.

In some embodiments, the process of Steps A-1 through A-5 can berepeated in series, one or more additional times, to form a plurality ofthicker, two- (or more-) layered circular base for a container body. Asecond layer of thermofusable powder material is deposited over theselectively-bonded first layer 775, and the shield 590 positioned withthe openings 592 in registry with the stabilized granular agglomerate734 of the first layer 775. The powder material exposed through theopenings 592 is thermally fused and bonded by the heat energy of thelaser light into a newly-formed stabilized granular agglomerate, whichalso bonds to the stabilized granular agglomerate 734 therebelow of theselectively-thermofused first layer 775.

In step B-1 shown in FIG. 68 , the upper surface 706 a of the removablebuild plate 706 is again lowered by an increment distance within thebuild module 700, re-forming a cavity 703 above the upper surface of theselectively-bound powder layer(s) 514.

In process step B-2 of FIG. 68 , another substantially uniform layer ofthermofusable powder 754 is deposited within the cavity 703, and itsupper surface 755 made level with (at the same height of) the positionof the upper surface 701 a of the build module.

In process step B-3 of FIG. 68 , a second shield 595 is positioned abovethe upper surface 755 of the second thermofusable powder layer 754. Theshield 595 is similar to the material and construction of the firstshield 590 described above, though having different openings formedthrough the planar material to expose the thermofusable powder layerbelow to a different pattern laser light. The second shield 595 isplaced above and substantially parallel to the upper surface 755 of thesecond thermofusable powder layer 754. To form a plurality of an annularwall portions onto the first or base layers 734 the thermofused firstlayer 775, the openings in the shield 595 is a substantially completeannular space 596 defined between the circular rims 598 and interior,central portions 597 that can be joined to the rim 598 by thinconnectors 599, as shown in FIG. 70 . The thin connectors aresufficiently narrow that they do not substantially interfere with theheating of the thermofusable powder material. The openings 596 arespaced apart in a selected pattern in the planar material, as shown inFIG. 70 , such that when the shield 595 is placed directly above, oralternatively spaced a suitable distance above, the upper surface 755 ofthe second powder layer 754, the openings 596 register with theperipheries of the stabilized granular agglomerate that forms the baselayers 734 in selectively thermofused first layer 755. It should beunderstood that the segment illustration shown in step B-3 of FIG. 68can extend across the entire build module.

After positioning of the shield 595, laser light 721 is emitted fromlight-emitting elements 723 of an energy source 722 as illustrated instep B-4. The laser light energy passing through the openings 596 in theshield 595 strikes the exposed portions 757 of the upper surface 755 ofthe second thermofusable powder layer 754, to heat the thermofusablepowder material beneath the exposed surface 757, which causes thethermal binder material within the thermofusable powder material tosoften and/or melt sufficiently. The energy intensity and duration canbe selected to provide sufficient softening and melting of the thermalbinder material in the exposed surface portions 757, while avoidingcomplete liquifying of the thermal binder material. The shield 595prevents or minimizes heating, and bonding or agglomeration, of thethermofusable powder material 754 in the shielded surface portions 758and 759, and will remain an unbonded and unfused powder material. Itshould be understood that the segment illustration shown in step B-4extends across the entire build module.

After the heat energy is stopped or removed, the shield 595 is removedfrom over the upper surface 755, revealing a selectively thermofusedsecond layer 776, as shown in step B-5. As the exposed heated powdermaterial cools, the thermofusable powder material beneath the exposedsurface 757 has bonded together into stabilized granular agglomerate,forming the thermofused second layer portions 736 that form the firstlayer of the peripheral wall of the container article. Each of thepatterned areas 736 of bound powder correspond to an area and thicknessof the peripheral wall for a dosage form, such as peripheral wall 6shown in FIG. 1 , while the thermofusable powder material 754 in theshielded portions 758 and 759 remain unbonded and free-flowing. Itshould be understood that the segment illustration shown in step B-5extends across the entire build module.

In some embodiments, the process of steps B-1 to B-5 of FIG. 68 arerepeated in series, one or more additional times, to form a peripheralcontainer wall consisting of two or more layers of the stabilizedgranular agglomerate, typically using the same thermofusable powdermaterial, shield 595 and heat source.

The thermofusing of the annular walls layers completes a container body,such as peripheral wall 92 shown in FIG. 11 . In some embodiments, thethermofusing process can be stopped and the thermofused container bodiesremoved from the build module and the removable build plate, andseparated from any unbound powder material.

In some embodiments, any unbound thermofusable powder material thatremains positioned between the outer surfaces of the formed containerbodies, or within the cavity of the container bodies, can be evacuated,using the means described and illustrated herein, for example, at FIGS.10-12 when forming separate-cavitied container bodies, or for example atFIG. 44 when forming a unitary, medicament-filled containers.

In the illustrated embodiment, a plurality of container bodies are beingformed within an open print bed. However, the person of ordinary skillunderstands that the steps of depositing a layer of thermofusable powdermaterial, positioning a shield over the upper surface of the powderlayer, and directing heat energy through the one or more openings in theshield to selectively bond the thermofusable powder material into astabilized granular agglomerate, can be performed within a depression orpocket of a packaging material, such as a blister.

In another embodiment, said means can comprise a heat source that passesheat energy into the layer of thermofusable powder material through theouter wall and/or base of a forming mold or blister package in which thedosage form is being formed in situ, which heats the thermofusablepowder material only around the periphery of the layer of powdermaterial, and thus limiting the penetration of heat energy into theinterior portions of the powder layer. A non-limiting example of suchtargeting heat energy can include a conductive heat source. The rate andtotal amount of heat energy transferred through the outer wall and/orbase of a forming mold or blister package can be controlled to effect araising of the temperature of the thermofusable powder material in theperipheral portions adjacent to the outer wall and/or base to a bulktemperature at or above the glass transition temperature of the thermalbinder, to softener and/or melt the thermal binder material only in suchperipheral portions to bond the other particulate components into abonded matrix. The interior portion of the layer of thermofusable powdermaterial, spaced a distance away from the outer wall and/or base, may beunheated or be limitedly heated such that the bulk temperature in theinterior portion of the layer of thermofusable powder material remainsbelow the glass transition temperature of the thermal binder, such thatthe particles of thermal binder material and the other particulate otherparticulate components remain solid, unbound, and un-agglomerated.

Upon cutting off of the heat transfer through the outer wall and/orbase, and/or extracting heat through the outer wall and/or base bycooling thereof, the bulk temperature drops below the glass transitiontemperature of the thermal binder, such that thermal binder materialre-solidifies to form a stabilized granular agglomerate in theperipheral portions of the layer. After sufficient cooling of the layerto ambient temperatures, the thermal binder material hardens to form astable granular agglomerate.

After the thermal binder has been heated to a temperature that softensand/or melts the thermal binder and binds the other particulatecomponents, the molten thermal binder material is cooled. The time andcooling medium temperature are such as to solidify the melted orsoftened thermal binder. Typically, the cooling medium is a gas, forexample, air, nitrogen, carbon dioxide, or other inert. In oneembodiment, the target cooling medium temperature is about 25° C. toabout 0° C., and the time of cooling is about 10 to about 60 seconds.Generally, the higher the cooling medium temperature during cooling, thelonger the cooling time. In one embodiment the cooling takes place atroom temperature (25° C.) for greater than 5 minutes.

In some embodiments, a means for heating the layer or layers of powdermaterial to a staging temperature that is below, though typically closeto, the glass transition temperature of the thermal binding material. Atthe staging temperature, the thermal binder material and the otherparticulate components remain solid and free-flowing. By raising thetemperature of thermofusable powder material to the staging temperature,the intensity and duration of heat applied by the laser light heatsource can be minimized when the heat source is directed at thepre-selected surface area of the layer of thermofusable powder material.As a result, the temperature of the thermofusable powder layer can moreefficiently be raised only at pre-selected portions of the surface areato approach an activating temperature near, at or above the glasstransition temperature of a thermal binder, while the portions that arenot selected or targeted for heating remain at, or near to, the stagingtemperature, and below the glass transition temperature of the thermalbinding material contained therein. Upon reaching the activationtemperature, the activated thermal binder can begin to soften, melt, andcohesively bind to adjacent particulate components in the thermofusablepowder material that remain solid, in order to form a bound matrix. Insome embodiments, the bulk thermofusable powder material is stored atthe staging temperature, and deposited into the layer of powder materialat the staging temperature. In some embodiments, the bulk thermofusablepowder material is heated to the staging temperature during its transferfrom its storage to its depositing into the layer of powder material. Insome embodiments, the thermofusable powder material is heated to thestaging temperature as or after it has been formed into the layer ofpowder material, and before activating or targeting of the selectedportions of the powder layer with heat energy.

The bound matrix formed by heating a thermofusable powder material iscapable of rapid dissolution upon contact with an aqueous liquid,including rapid orodispersibility, under the same conditions and to thesame extend as a bound matrix described herein that is formed bydepositing and/or forming a layer of powder material and wetting with abinding liquid.

In another embodiment, rapidly-orodispersible dosage forms of thepresent invention can be characterized by their overall hardness andfriability characteristics. In another embodiment, the hardness of thematrix can be the same (uniform) throughout the matrix. In anotherembodiment, hardness of the matrix can vary within the same matrix. Inanother embodiment, a container body can have a hardness that is within+/−10% of the hardness of the container body within the same dosageform. In another embodiment, the container body and the lidding body inthe same dosage form have the same hardness. In some embodiments, thehardness of one portion of the dosage form can be greater than thehardness of another portion of the dosage form. In a non-limitingexample, and in another embodiment, the one or more base layers of thedosage form can have a hardness that is greater than the layerscomprising the peripheral wall and/or the upper portion of the dosageform, to provide additional protection against dropping the dosage form.In another embodiment, the hardness of the base portion of the dosageform can be at least 1.05-fold, at least 1.1-fold, at least 1.2-fold, atleast 1.3-fold, at least 1.4-fold, at least 1.5-fold, at least1.75-fold, at least 2-fold, at least 2.5-fold, at least 3-fold, at least5-fold, at least 7-fold, or at least 10-fold higher than other portionsof the dosage form.

In another embodiment, some embodiments, the dosage form has an overallhardness that gives the dosage form a shelf life of at least six months.In another embodiment, some embodiments, the dosage form has an overallhardness that gives the dosage form a shelf life of at least one year.In another embodiment, rapidly-orodispersible container and/or liddingbodies stored separately from each other have a shelf life of greaterthan one year.

In another embodiment, the overall hardness (as determined by a tabletbreaking force assay according to USP <1217>) of rapidly-orodispersibledosage form, rapidly-orodispersible container, and/orrapidly-orodispersible lidding body can be in a range selected from thegroup consisting of: from at least about 1 kp, up to about 20 kp; fromat least about 1 kp, up to about 10 kp; from at least about 1 kp, up toabout 7 kp; from at least about 3 kp, up to about 9 kp; from at leastabout 1 kp, up to about 3 kp; from at least about 4.5 kp, up to about 6kp; from at least about 2.5 kp, up to about 6.5 kp; from at least about3 kp, up to about 6 kp; or from at least about 1 kp, up to about 5 kp.In another embodiment, the overall hardness of therapidly-orodispersible dosage form, container body, and/or lidding bodyis at least 1 kp, or at least 2 kp, or at least 3 kp. In anotherembodiment, the overall hardness of the rapidly-orodispersible dosageform, container body, and/or lidding body is no more than 10 kp, or nomore than 8 kp, or no more than 6 kp.

The friability of the rapidly-orodispersible dosage form, containerbody, or lidding body refers to the tendency of the bound-powder matrixto lose material from its outer edges and surfaces upon manipulation orhandling. As the hardness of the object is increased, the friability isreduced. In another embodiment, the rapidly-orodispersible dosage form,container body, or lidding body can possess a friability of less thanabout 25%, and is preferably less than about 10%, as determinedaccording to USP chapter <1216>.

An article of the present invention shall have sufficient integrity toallow for packaging, storage, and transportation of the article to auser, as well as sufficient integrity while opening of its packaging andadministering to the user or third person. In some embodiments, anarticle comprising a container body and lidding body shall have asufficient level of fixation or securement between the container bodyand the lidding body, whether by an adhesive securement or a mechanicalsecurement, or a combination thereof, such that the article may beinverted without separation of the lidding body from the container body,or without loss or spillage of any contents contained within thearticle, such as a particulate material or medicament housed containedwithin the article. In some embodiments the strength of fixation betweencontainer body and lidding body is sufficient to sustain the suspendedweight of the lidding body, container body, and/or any contents of thearticle without failure. In some embodiments, the fixation of thelidding body to the container body is sufficient to bear a tensile loadgreater than or equal to 0.005 N, greater than or equal to 0.01 N,greater than or equal to 0.02 N, greater than or equal to 0.05 N, orgreater than or equal to 0.1 N, without failure. In some embodiments, anarticle of the present invention tested for tablet hardness (i.e.,tablet breaking force, USP <1217>) exhibits a hardness of greater than0.5 kp, greater than 1.0 kp, greater than 1.5 kp, greater than 2.0 kp,greater than 3.0 kp, greater than 4.0 kp, greater than 5.0 kp, orgreater than 10.0 kp. In some embodiments, an article of the presentinvention can sustain both the tensile loads and the compressive loads(breaking force) as described above, or elsewhere herein, alone or incombination with other features of the present invention.

In another embodiment, the porosity of the bound-powder matrixcomprising the rapidly-orodispersible dosage form, container body, orlidding body can be in a range from at least about 10%, up to about 90%;or from at least about 30%, up to about 70%, of the overall volume ofthe matrix. In another embodiment, the bulk density of the bound-powdermatrix (as determined by measurement and/or calculation) can be in arange from at least about 150 mg/mL, up to about 1300 mg/mL; or from atleast about 400 (mg/mL), up to about 1000 (mg/mL).

In another embodiment, the dissolution time of the one or moremedicaments is slower than, and independent of, the dispersion time ofthe rapidly-orodispersible dosage form itself when placed in an aqueousfluid. In another embodiment, rapid dissolution of the medicament(s) canbe achieved, wherein not less than 75% by weight (or wherein at least75% by weight) of the one or more medicaments contained within therapidly-orodispersible dosage form dissolves in a time selected from thegroup consisting of: 20 minutes or less; 10 minutes or less; 5 minutesor less; 4 minutes or less; 3 minutes or less; 2 minutes or less; or 1minute or less, when placed in an aqueous environment, such as, in anon-limiting example, within a subject's digestive tract. In anotherembodiment, not less than 95% by weight (or at least 95% by weight) ofthe one or more medicaments contained within the rapidly-orodispersibledosage form dissolves in a time selected from the group consisting of:20 minutes or less; 10 minutes or less; 5 minutes or less; 4 minutes orless; 3 minutes or less; 2 minutes or less; or 1 minute or less, whenplaced in an aqueous environment.

In an alternative embodiment, controlled release of the medicaments canbe achieved, in which only a small portion of the medicament(s)dissolves within a given time period. In a non-limiting example, and inanother embodiment, not more than 50% by weight (or wherein less than50% by weight), of the one or more medicaments contained within therapidly-orodispersible dosage form dissolves in a time selected from thegroup consisting of: 20 minutes or less; 10 minutes or less; 5 minutesor less; 4 minutes or less; 3 minutes or less; 2 minutes or less; or 1minute or less, when placed in an aqueous environment. In anotherembodiment, not more than 10% by weight, (or wherein less than 10% byweight), of the one or more medicaments contained within therapidly-orodispersible dosage form dissolves in a time selected from thegroup consisting of: 20 minutes or less; 10 minutes or less; 5 minutesor less; 4 minutes or less; 3 minutes or less; 2 minutes or less; or 1minute or less, when placed in an aqueous environment.

In another embodiment, the controlled dissolution of the one or moremedicaments can alternatively be defined by the mass percent of themedicament(s) dissolved within an aqueous fluid in a specified time. Inanother embodiment, the mass percent of the one or more medicaments thatare dissolved 10 minutes after placing a rapidly-orodispersible dosageform in the aqueous fluid can be a value selected from the groupconsisting of: less than 50% by weight; less than 45% by weight; lessthan 40% by weight; less than 35% by weight; less than 30% by weight;less than 25% by weight; less than 20% by weight; less than 15% byweight; less than 10% by weight; less than 5% by weight; and less than1% by weight. In another embodiment, less than 40% by weight of the oneor more medicaments is dissolved 10 minutes after placing therapidly-orodispersible dosage form in an aqueous fluid. In anotherembodiment, less than 30% by weight of the one or more medicaments isdissolved 10 minutes after placing the rapidly-orodispersible dosageform in an aqueous fluid.

In another embodiment, the mass percent of the one or more medicamentsthat are dissolved 2 minutes after placing a rapidly-orodispersibledosage form in the aqueous fluid can be a value selected from the groupconsisting of: less than 20% by weight; less than 15% by weight; lessthan 10% by weight; less than 8% by weight; less than 6% by weight; lessthan 5% by weight; less than 4% by weight; less than 3% by weight; lessthan 2% by weight; and less than 1% by weight. In another embodiment,less than 8% by weight of the one or more medicaments is dissolved 2minutes after placing the rapidly-orodispersible dosage form in anaqueous fluid. In another embodiment, less than 4% of the one or moremedicaments is dissolved 2 minutes after placing therapidly-orodispersible dosage form in an aqueous fluid.

In some embodiments, any of the dissolution times above may be achievedin aqueous environments characterized by a pH of 1.2 or 4.5 or 6.8, andtested within a USP paddle apparatus at 50 RPM or 75 RPM or 100 RPM anda volume of 900 mL or 950 mL or 1000 mL.

In view of the above description and the examples below, one of ordinaryskill in the art will be able to practice the invention as claimedwithout undue experimentation. The foregoing will be better understoodwith reference to the following examples that detail certain proceduresfor the preparation of embodiments of the present invention. Allreferences made to these examples are for the purposes of illustration.The following examples should not be considered exhaustive, but merelyillustrative of only a few of the many embodiments contemplated by thepresent invention.

EXAMPLES

The following working and prophetic examples illustrate the embodimentsof the invention that are presently best known. However, it is to beunderstood that the following are only exemplary or illustrative of theapplication of the principles of the present invention. Numerousmodifications and alternative compositions, methods, and systems may bedevised by those skilled in the art without departing from the spiritand scope of the present invention. Thus, while the present inventionhas been described above with particularity, the following examplesprovide further detail in connection with what are presently deemed tobe the most practical and preferred embodiments of the invention.

Example 1: Preparation of a Unitary Rapidly-Orodispersible Dosage FormHaving a Medicament Contained within an Internal Cavity

The following materials and process was used to prepare athree-dimensionally printed, unitary rapidly-orodispersible dosage formhaving a medicament contained within an internal cavity. A plurality oftablets were formed within a series of pre-formed, thermoformed blisterdepressions. The ingredients for the printing fluid and the powdersused, as well as the build sequence, are indicated below:

TABLE 1 Printing Fluid Component % w/w 25 mM Phosphate Buffered Solution72.0 Polysorbate 20 1.90 Isopropyl Alcohol 12.3 Glycerin 3.80 PovidoneK29/32 10.00 Total 100

TABLE 2 Powder 1 Component % w/w Mannitol 50C 42.5 Mannitol 160C 42.5Avicel PH101 7.0 Povidone K29/32 7.0 Cab-O-Sil 1.0 Total 100

TABLE 3 Medicament Powder % w/w Compound A with Tastemask Coating 100Total 100

TABLE 4 Build Sequence Sequence # Step Conditions 1 Print 2 layersPrinting fluid, 1800 DPI, 17.2 mm Circle pattern 2 Dispense and levelPowder 1, ~175 mg 3 Print 2 layers Printing fluid, 1800 DPI, 17.5 mm,1.5 mm Ring pattern 4 Dispense and level Powder 1, ~175 mg 5 Print 2layers Printing fluid, 1800 DPI, 17.8 mm, 1.5 mm Ring pattern 6 Dispenseand level Powder 1, ~175 mg 7 Print 2 layers Printing fluid, 1800 DPI,18.1 mm, 1.5 mm Ring pattern 8 Dispense and level Powder 1, ~175 mg 9Print 2 layers Printing fluid, 1800 DPI, 18.4 mm, 1.5 mm Ring pattern 10Dispense and level Powder 1, ~175 mg 11 Print 2 layers Printing fluid,1800 DPI, 18.8 mm, 1.5 mm Ring pattern 12 Vacuum loose Powder 1 fromcenter 13 Dispense and level Medicament Powder, 200 mg 14 Dispense andlevel Powder 1, ~175 mg 15 Print 2 layers Printing fluid, 1800 DPI, 18.8mm, 1.5 mm Ring pattern 16 Dispense and level Powder 1, ~175 mg 17 Tamp3.0 mm, Flat 18 Print 4 Layers Printing fluid, 900 DPI, 19.2 mm, Circlepattern

The formed tablet within the blister depression was then air dried.Tablet hardness ranged from 1.4 to 3.4 kp. Oral disintegration time ofthe tablet ranged from 6.8 to 27.0 seconds.

Example 2: Preparation of a Two-Piece Rapidly-Orodispersible PlaceboDosage Form Having a Solid Payload Material Contained within an InternalCavity

Three-dimensionally printed, rapidly-orodispersible dosage forms havinga solid material contained within an internal cavity were prepared. Aplurality of dosage forms were produced in an open body within a buildmodule, using the procedures described in U.S. Pat. No. 8,888,480. Eachdosage form was assembled from two pieces—a container body and a liddingbody—which were secured together by the application of the adhesivefluid. Container bodies were formed separately from lidding bodies. Thepowder material was the same Powder 1 used in Example 1. The componentsof the printing fluid and the adhesive fluid are indicated below:

TABLE 5 Printing Fluid Component % w/w Water 72.0 Polysorbate 20 1.90Isopropyl Alcohol 12.3 Glycerin 3.80 Povidone K29/32 10.00 Total 100

TABLE 6 Adhesive Fluid Component % w/w Water 42.5 Isopropyl Alcohol 42.5Hydroxypropyl Cellulose 15.0 Total 100

The plurality of container bodies were formed using a similar buildsequence as described above in Example 1, with the formation of a solidbase layer, followed by a plurality of incremental intermediate layersprinted in a ring pattern to form the peripheral wall of the containerbody. The pattern of printing fluid applied to the uppermost layer ofthe peripheral wall was adjusted to form a pair of congruently-shapedslots into opposite sides of the peripheral wall's upper surface,substantially as illustrated in FIG. 35 . Each lidding body was formedusing a similar procedure to the base layer of the container body,except that a pair of rectangularly-shaped pins were formed to extendfrom opposite sides of an outer surface of the peripheral edge of thelidding body, also as shown in FIG. 35 .

Once formed, lidding bodies and container bodies were dried in aconvection oven at 60° C. and were separated from loose unprinted powderwith vacuum and compressed air. The central cavities of each containerbody were partially filled with Powder 1 as a placebo material andleveled, until the depth of the powder material below the upper surfaceof the peripheral was approximately the same as the thickness of thelidding body. Instead of using Powder 1 as a placebo material, amedicament, such as the medicament in Example 1, can be used to fill thecavity. Lidding bodies were adhered to the container body using theadhesive fluid, with the lidding body pins in register with the slotsformed into the container body, to produce the dosage form substantiallyas illustrated in FIG. 36 . All of the dosage forms were dried overnightin ambient conditions.

The hardness of the dosage forms ranged from 3.6 to 7.5 kp and theirdisintegration time ranged from 3 to 17 seconds.

Example 3: Preparation of a Unitary Rapidly-Orodispersible Dosage FormHaving a Solid Payload Contained within an Internal Cavity

The following materials and process are used to preparethree-dimensionally printed, rapidly-orodispersible dosage forms havinga solid payload contained within an internal cavity. The ingredients forthe printing fluid and the powders are indicated below:

TABLE 7 Printing Fluid Component I-A I-B I-C I-D I-E (% w/w) Low HighLow High Low High Low High Low High Water 65 75 65 75 65 75 65 75 25 mMPhosphate 65 75 Buffered Solution Polysorbate 20 1.5 2.5 1.5 2.5 1.5 2.51.5 2.5 1.5 2.5 Isopropyl Alcohol 10 15 10 15 10 15 10 15 Ethanol 10 15Glycerin 3.5 4.5 3.5 4.5 3.5 4.5 3.5 4.5 3.5 4.5 Povidone K29/32 8.510.5 8.5 10.5 8.5 10.5 8.5 10.5 Copovidone 8.5 10.5 Sucralose 5 Total88.5 107.5 88.5 107.5 88.5 107.5 88.5 112.5 88.5 107.5

TABLE 8 Powder 1 Component II-A II-B II-C II-D II-E (% w/w) Low High LowHigh Low High Low High Low High Mannitol 80 90 60 80 60 80 Lactose 60 8060 80 Microcrystalline 5 10 10 20 10 20 5 15 5 15 Cellulose PovidoneK29/32 5 10 10 20 5 15 5 15 Copovidone 5 25 Starch 5 15 5 15 ColloidalSilica 2 2 2 2 2 Total 90 112 80 122 75 127 75 127 75 127

A predetermined mass or volume of Powder 1 is dosed into a preformedblister cavity and leveled to form an incremental layer having asubstantially uniform thickness. Printing fluid is applied to theincremental layer as droplets according to a pre-determined shapepattern, saturation level, line spacing and printing fluid flow rate tobind the particles therein. A base is formed by applying printing fluidto substantially all of the surface area of one or more incrementallayers to form a bound matrix. Peripheral walls are formed atop andbound to the base by applying printing fluid only to a perimeter portionof one or more incremental intermediate layers, while leaving a centralportion of each intermediate layer unbound. Any of Printing Fluids I-Athrough I-E are used. Any of the Powder 1 II-A through II-E are used.Some dosage forms comprise a single Printing Fluid I-A through I-E and asingle Powder 1 II-A through II-E.

The process is repeated until a container is formed having a base and aperipheral wall extending from the base. Loose, unbound Powder 1 withinthe container portion is removed by vacuum or compressed air. Medicamentpowder III-A through III-E are placed and leveled in the container shapeusing volumetric or gravimetric dosing means. Powder 1 and PrintingFluid are then applied to the shared surface formed by the MedicamentPowder and upper surface of the peripheral wall, using a similarprocedure as used to form the base, above, to enclose the MedicamentPowder and build an upper matrix portion of the dosage form. Theresulting unitary 3DP rapidly-orodispersible dosage form is dried by anysuitable means to reduce the amount of solvent and moisture to a desiredlevel.

TABLE 9 Medicament Powder III-A III-B III-C III-D III-E (% w/w) Low HighLow High Low High Low High Low High Compound A with 80 100 40 50Tastemask Coating Compound B with 80 100 40 50 Extended Release CoatingCompound C Granule 80 100 with Solubility Enhancer Compound D Granule 80100 with Permeability Enhancer Microcrystalline 0 20 0 20 0 20 0 20 0 20Cellulose Crospovidone 0 10 0 10 0 10 0 10 0 10 Sodium Starch 0 10 0 100 10 0 10 0 10 Glycolate Colloidal Silica 0 2 0 2 0 2 0 2 0 2 Total 80142 80 142 80 142 80 142 80 142

In an alternative to filling the central cavity with any of theMedicament Powders III-A through III-E, any solid material can insteadbe utilized, for example, any of the Powder 1 materials II-A throughII-E.

Example 4: Preparation of a Two-Piece Rapidly-Orodispersible Dosage FormHaving a Solid Payload Contained within an Internal Cavity

The following materials and process are used to preparethree-dimensionally printed, rapidly-orodispersible dosage forms havinga solid payload contained within an internal cavity. Any of the PrintingFluids I-A through I-E, Powder 1 materials II-A through II-E, orMedicament Powders III-A through III-E described in Example 3 above canbe utilized.

A container body, comprising a base portion and a peripheral wall, canbe formed using the procedures described in U.S. Pat. No. 8,888,480and/or in Example 2 above. A lidding body is formed separately usingsimilar procedures as for the container body, and comprising either anidentical powder composition or a different powder composition relativeto the container body. The lidding body is formed to have acomplementary shape to the upper surface of the container, such that thecentral cavity of the container can be enclosed by the lidding body uponassembly.

The container body and lidding body are dried by any suitable means toreduce the amount of solvent and moisture to a desired level and areseparated from loose unprinted powder with vacuum or compressed air. Thedosage form is assembled by filling the central cavity of the containerwith any of the Medicament Powders III-A through III-E above, with anyof the Powder 1 materials II-A through II-E, or other solid material.The lidding body is placed atop the filled container and adhered, fixed,or otherwise secured to the container body by mechanical locking, orapplication of a polymer solution or low-melting material as anadhesive. If polymer solution is used, the resulting two-piece 3DPrapidly-orodispersible dosage form is dried by any suitable means toreduce the amount of solvent and moisture to a desired level.

Example 5: Characterization of Dosage Forms

The following procedures are used to characterize thethree-dimensionally printed rapidly-orodispersible dosage forms

Surface Texture and Visual Inspection

The dosage forms are inspected visually with or without the aid of amicroscope. The surface texture is analyzed to determine if it is roughor smooth and whether the edges of indicia on the upper surface and theedges of the perimeter of the wafer are clean and sharp or rough andjagged.

Hardness

The dosage forms are analyzed for overall hardness as determined by atablet breaking force assay according to USP <1217> (31st edition) usinga VK 200 tablet hardness tester (Varian, US). The strength or hardnessis measured by a fracture test, in which a dosage form is centeredbetween the jaws of the tester and force is applied until the dosageform fractures. The load at fracture is returned in kilogram-force, orkiloponds (kp). A kilopond is a metric unit of force measurement with 1kp being equivalent to 9.807 Newtons. A minimum number of 6 dosage formsare tested. The hardness of the dosage forms ranges from about 0.5 kp toabout 3.0 kp.

Dispersion Time

The dosage forms are analyzed for dispersion time in aqueous fluidaccording to protocols set forth within USP <701>, using a basket-rackassembly to immerse one or more tablet into a liquid, preferably water.An uncoated or plain-coated tablet is placed into a receptacle or tubewithin the basket, and the basket immersed into the immersion liquid,which is maintained at 37+/−2° C. Tablets containing a delayed- orextended-release coating are immersed into a fluid that simulatesphysiological conditions within the stomach or intestines, depending onthe desired release location.

The dispersion time for the dosage forms range from 7 seconds to 27seconds.

Bulk Density

The bulk density of the matrix is determined by measuring the weight ofthe dosage form and dividing that value by the calculated volume of thedosage form. The volume is calculated by measuring the dosage form'sdimensions and using the proper mathematical formula according to theshape of the dosage form. For example, for a frustoconical dosage form,the volume of which is calculated using the form π-r²*H, wherein r isthe average radius of the top and bottom surfaces of the dosage form andH is its height. Accordingly, a dosage form weighing 1.05 g, having aheight of 0.537 cm and an average radius of 0.782 cm, has a volume ofabout 1.032 cm³, and a bulk density of about 1.021 g/cm³, which isequivalent to about 1021 mg/ml.

Dissolution of the API

Dissolution testing is conducted according to the Guidance for Industry(See Section 3.3.2; Waiver of In Vivo Bioavailability and BioequivalenceStudies for Immediate-Release Solid Oral Dosage Forms Based on aBiopharmaceutics Classification System. August 2000. Section Inc, p 7).The method of USP <711> was followed. Dissolution is performed using aUSP Apparatus II (paddle) at 100 rpm using 900 mL of the followingde-aerated dissolution media: simulated saliva (10 mM sodium phosphate,15 mM sodium chloride, pH 6.5 buffer at 37° C. 1.7% of the Compound Awas released after 2 minutes.

Because the instant application is a continuation or divisionalapplication, to the extent any amendments, characterizations, or otherassertions previously made (in any related patent applications orpatents, including any parent, sibling, or child) with respect to anyart, prior or otherwise, could be construed as a disclaimer of anysubject matter supported by the present disclosure of this application,Applicant hereby rescinds and retracts such disclaimer. Applicant alsorespectfully submits that any prior art previously considered in anyrelated patent applications or patents, including any parent, sibling,or child, may need to be re-visited.

1.-15. (canceled)
 16. A method for forming a container body having anempty cavity, the method comprising the steps of: i) forming a containerbase, comprising the steps of: a) dispersing a first ingestible buildpowder material into a base powder layer; b) dispensing a first bindingliquid onto the base powder layer to form a first base level of abound-powder matrix; and c) optionally repeating steps a) and b) one ormore times to form a second or more base level of the bound-powdermatrix, and thereby forming the container base; ii) forming a peripheralwall, comprising the steps of: d) dispersing a second ingestible buildpowder material into an intermediate powder layer atop the containerbase; e) dispensing a second binding liquid onto a peripheral portion ofthe intermediate powder layer in registry with a periphery of thecontainer base, without dispersing the second binding liquid onto aninterior portion of the intermediate powder layer, to form a firstperipheral wall level of a bound-powder matrix that is bound to thecontainer base, and having an interior filled with unbound build powdermaterial; and f) optionally repeating steps d) and e) one or more timesto form a second or more peripheral wall level of the bound-powdermatrix, and thereby forming the peripheral wall bound to the containerbase; and iii) removing the unbound second build powder material of theintermediate powder layer, thereby forming the container body having anempty cavity and comprising the container base and the peripheral wall.17. The method of claim 16, wherein the first build powder material andthe second build powder material independently comprise one or morepharmaceutical excipients selected from the group consisting of a solidbinder material, a disintegration agent, a dispersant, a sweetener, aglidant, a flavoring agent, a surfactant, a humectant, a preservative,an antioxidant, a solvent, a diluent, and combinations thereof, and thefirst binding liquid and the second binding liquid independentlycomprise one or more pharmaceutical excipients selected from the groupconsisting of: a disintegration agent, a humectant, a sweetener orflavoring agent, a preservative, a solvent, and a surfactant, andcombinations thereof.
 18. The method according to claim 16, wherein thestep of removing the unbound second build powder material from thefilled container body comprises the sub-steps of at least one of: (a)providing a vacuum system comprising an air inlet and an air drawingmeans for drawing an ambient air into the air inlet; positioning the airinlet over the filled container body; drawing ambient air into thepositioned air inlet to fluidize the unbound second build powdermaterial within the filled container body; and drawing the unboundsecond build powder within the filled container body into the air inletwith the ambient air; and (b) inverting the filled container body, anddecanting the unbound second build powder material from the filledcontainer body.
 19. The method according to claim 18, wherein the methodfurther comprises the steps of: recovering the removed unbound secondbuild powder material using a build powder recovery system; andreturning the recovered unbound second build powder material to a buildpowder reservoir.
 20. The method according to claim 16, furtherincluding the steps of: iv) dispersing one or more particulate payloadmaterial into the cavity; v) forming an upper layer of a third buildpowder material over the cavity and the upper surface of the container'speripheral wall; vi) dispensing a third binding liquid onto a portion ofthe upper layer of the third build powder material, to form abound-powder upper layer atop the cavity, forming the interior cavitycontaining the one or more particulate payload material; and vii)optionally performing steps iii) and iv) one or more times, therebyforming the dosage form.
 21. The method according to claim 20, whereinthe step of dispensing the one or more particulate payload materialcomprises the further sub-step of dispensing one or more fillermaterials onto the dispensed particulate payload material, until thecavity is filled.
 22. A method for forming a dosage form containing asolid medicament within an interior cavity of the dosage form,comprising the steps of: (a) providing a porous, durable container bodymade of a first bound-powder material, the container body having a base,a peripheral wall extending from the base and having an inner surface,an upper surface, and an external surface, the container body having oneor more empty cavities bounded by the base and the inner surface of theperipheral wall; (b) providing a porous, durable lidding body comprisinga second bound-powder material; (c) dispensing a one or more particulatepayload materials, the one or more particulate payload materialscomprising a medicament, into the one or more empty cavity; (d) placingthe lidding body onto the upper surface of the peripheral wall, to forman internal cavity containing the one or more particulate payloadmaterials; and (e) securing the lidding body to the container body,thereby forming the dosage form.
 23. The method according to claim 22,wherein at least one of the container body and the lidding body furthercomprises an adhesive material, the adhesive material disposed on, andapplied to, at least a portion of a surface selected from the groupconsisting of the upper surface of the peripheral wall of the containerbody, the inner surface of the peripheral wall of the container body, aperipheral portion of an undersurface of the lidding body, an annularouter surface of a projection portion of the lidding body, andcombinations thereof; and adhering the lidding body to the containerbody through the adhesive material.
 24. The method according to claim23, wherein the adhesive material comprises a thermally-activatedadhesive compound.
 25. The method according to claim 24, wherein thethermally-activated adhesive compound is a component of the build powdermaterial. 26.-41. (canceled)
 42. The method according to claim 16,wherein at least one of the first ingestible build powder material andthe first binding liquid comprises an ingestible binder material, and atleast one of the second ingestible build powder material and the secondbinding liquid comprises an ingestible binder material.
 43. A method forforming a container body having an empty cavity, the method comprisingthe steps of: i) forming a container base, comprising the steps of: a)dispersing a first ingestible build powder material into a base powderlayer; b) dispensing a first binding liquid onto the base powder layerto form a first base level of a bound-powder matrix; and c) optionallyrepeating steps a) and b) one or more times to form a second or morebase level of the bound-powder matrix, and thereby forming the containerbase; ii) forming a peripheral wall, comprising the steps of: d)dispersing a second ingestible build powder material into anintermediate powder layer; e) dispensing a second binding liquid onto aperipheral portion of the intermediate powder layer, without dispersingthe second binding liquid onto an interior portion of the intermediatepowder layer, to form a first peripheral wall level of a bound-powdermatrix, and having an interior filled with unbound second build powdermaterial; and f) optionally repeating steps d) and e) one or more timesto form a second or more peripheral wall level of the bound-powdermatrix, and thereby forming the peripheral wall; wherein the peripheralportion of the intermediate powder layer is in registry with and boundto the periphery of the container base; and iii) removing the unboundsecond build powder material of the intermediate powder layer, therebyforming the container body having an empty cavity and comprising thecontainer base and the peripheral wall.